Valve Stem Seals, Replacing With Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal3364
• Seal Installer - Valve Stem3365
• Valve Cotter Tool KitVAS5161A with Valve Cotter Tool Kit - PunchVAS5161/3A, Valve Cotter Tool Kit - Assembly CartridgeVAS5161/8A and Valve Cotter Tool Kit - Guide Plate 29VAS5161/29.
• Engine and Gearbox Bracket VAS6095AVAS6095A
• Cylinder Head Tensioning DeviceVAS 6419

Procedure

-- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

-- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

-- Insert the Cylinder Head Tensioning DeviceVAS6419 in the Engine and Gearbox BracketVAS6095A.

Fig 1: Identifying Air Cushion With Lever

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-- Tension the cylinder head on the cylinder head tensioning device, as illustrated.

-- Connect the cylinder head tensioning device to the compressed air.

-- Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seal that will be removed.

-- Let enough compressed air flow into the air cushion until it contacts the valve plate.

-- Mark the roller rocker lever so it can be installed later and remove them.

-- Place the Valve Cotter Tool Kit - Guide PlateVAS5161A/29 on the cylinder head.

Fig 2: Identifying Valve Keeper Tool Kit - Guide Plate VAS 5161A/29

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-- Secure the guide plate with the Valve Cotter Tool Kit - Knurled ScrewsVAS5161/12.

-- Insert the Valve Cotter Tool Kit - PunchVAS5161/3 A in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- Install the Valve Cotter Tool Kit - RetainerVAS5161/6 with the Valve Cotter Tool Kit - Threaded StudsVAS5161/5 in the guide plate.

Fig 3: Identifying Retainer VAS 5161/6 With Threaded Studs VAS 5161/5

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-- Insert the Valve Cotter Tool Kit - Installation CartridgeVAS5161/8A into the opening above the soon to be removed valve spring.

-- Engage the Valve Cotter Tool Kit - Pressure ForkVAS5161/2 at the engaging device and press the installation cartridge downward.

-- At the same time, rotate the cartridge knurled screw right until points engage in valve retainers.

-- Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the cartridge.

-- Release the pressure fork.

-- Remove the installation cartridge with the knurled spacer ring.

-- Remove the valve spring and the valve spring plate.

-- Remove the valve stem seal with the Puller - Valve Seal3364.

Fig 4: Identifying Puller - Valve Seal 3364

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Fig 5: Identifying Plastic Sleeve, New Valve Stem Oil Seals & Valve Stem Seal Driver 3365

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-- Lightly oil the valve stem seal.

-- Slide the valve stem seal onto the plastic sleeve.

-- Carefully press the valve stem seal onto the valve guide with the Seal Installer - Valve Stem3365.

-- Remove plastic sleeve.

If the valve retainers were removed from the installation cartridge, they must then be inserted into the Valve Cotter Tool Kit - Valve Insertion DeviceVAS5161/18.

Fig 6: Identifying Installation Cartridge VAS 5161/8

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• The large diameter of the valve retainers point upward.

-- Insert valve spring and valve spring plate.

-- Press the cartridge from above onto the insertion device and capture retainers.

-- Insert the cartridge into the Valve Cotter Tool Kit - Guide PlateVAS5161A/29.

Fig 7: Identifying Retainer VAS 5161/6 With Threaded Studs VAS 5161/5

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-- Press the pressure fork down and pull the knurled screw up while turning left and right. This inserts the valve retainers.

-- Release the pressure fork with the knurled screw still raised.

-- Repeat the procedure on each valve.

Assembling

Assembly is performed in reverse order of removal.