Why: 1. Very common for the valve cover gaskets to leak.
2. A lot of people like to paint or powder coat their valve covers to improve the appearance.
3. The valve covers warp too which can cause an oil leak.
4. The inside of the metal style valve covers are painted and the paint flakes off so a lot of people like to clean it off completely to prevent the paint from building up in the oil pump pickup tube.
Previous steps required:
- Lower fuel pressure. http://audirevolution.net/forum/index.php?topic=2917.0
- Removing the MAF boot and top half of the engine air box. http://audirevolution.net/forum/index.php?topic=2919.0
- Loosening the coolant tank so that it can be moved around for clearance. http://audirevolution.net/forum/index.php?topic=2921.0
- Removing the ignition coils and moving the ignition coil wiring harness out of the way. http://audirevolution.net/forum/index.php?topic=2943.0
Parts required:
- Valve cover gaskets - the outer ring gaskets, spark plug hole gaskets, and half moon seals.
- Clamps - there are two PCV lines that connect to the back of the valve covers and Audi uses one time use crimp style clamps from the factory
- PCV grommets - part # 079103487A - 2004s and 2005s up to VIN 8E-5-118000 have grommets under the valve covers that direct the flow for the PCV channels.
- Valve covers - Audi has gone to plastic valve covers instead of the older metal valve covers.
- Valve cover bolts - if stripped or rounded
http://c1552172.r72.cf0.rackcdn.com/361005_x600.jpg
Tools required:
- 14 mm wrench
- 17 mm wrench
3a. Stubby T30 torx 1/4 drive socket and fine 70+ teeth 1/4 drive ratchet - like the socket and ratchet on the left in the below picture.
http://i284.photobucket.com/albums/ll37/Jimmybones777/Picture035.jpg
3b. Or a T30 bit and fine teeth bit driver
- Prybar
- Ball end 5 mm Allen socket 1/4 drive socket
Steps:
- Move everything out of the way: coolant tank, ignition coil wiring harnesses, etc.
- Use the 14 mm wrench to hold the fuel rail line and the 17 mm wrench to loosen the fuel rail line towards the back left of the intake manifold. I like to put a rag under the connection to catch any remaining fuel. Then shove the fuel line between the air box and the body.
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161238_resized_zps3c32544d.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161342_resized_zps5e82b0c5.jpg
- Loosen the clamps that hold the PCV lines to the back of the valve covers.
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161438_resized_zpsb3881668.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161535_resized_zpsac14c60f.jpg
- Loosen the lower back corner bolts, the bolt under the ABS control module brackets, and the bolt next to the dipstick tube. This is the point of no return because if you can’t get these bolts loose then there is no point in going any further. I like to use a prybar to hold the ratchet and stubby T30 torx socket or T30 bit and bit driver in place so it doesn’t round out the lower rear corner bolts. Trust me, you really don’t want to round out these bolts!
Passenger’s side rear lower bolt:
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140902_190610_resized_zps01bd2e29.jpg
Driver’s side rear lower bolt:
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140902_190541_resized_zps41c800d4.jpg
I also struggle with this lower bolt on the driver’s side valve cover. It is under the bracket for the ABS control module.
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140902_190557_resized_zpsece00a6b.jpg
I like to loosen or take out the dipstick tube bolt to get some more room. It is a 5 mm allen but you need a ball end Allen socket to get on it.
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161602_resized_zps90c7e03b.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161620_resized_zps62bc6037.jpg
- Once you have those four bolts loose then loosen the other twenty six bolts and remove the valve covers. The rest are a cake walk once those tough four are loose.
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161456_resized_zps8ab5e1dd.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161501_resized_zpsc77fa258.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161521_resized_zpsebfdc3e4.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161511_resized_zps90a3fbca.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161449_resized_zps9bd47f82.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/20140903_161547_resized_zpse0f99af5.jpg
- Once the valve covers are off then you can change out the gaskets and PCV grommets if your car has them. The bolts hold the outside edge gaskets and middle bolt gasket in place so you have to press the gasket into the metal sleeve of the bolts. This is also a good time to take the paint off the inside of the metal valve covers and paint or powdercoat the outside of the valve covers.
http://i284.photobucket.com/albums/ll37/Jimmybones777/Picture023.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/Picture030.jpg
Be sure to cut and remove the little strip of gasket between the middle gasket and the edge.
http://i284.photobucket.com/albums/ll37/Jimmybones777/mycleanedengine9.jpg
http://i284.photobucket.com/albums/ll37/Jimmybones777/mycleanedengine10.jpg
