Valve Stem Seals, Replacing, Cylinder Head Installed

Special tools and workshop equipment required 

• Puller - Valve Seal3364
• Seal Installer - Valve Stem3365
• Valve Cotter Tool KitVAS5161A with Valve Cotter Tool Kit - PunchVAS5161/3AA, Valve Cotter Tool Kit - Assembly CartridgeVAS5161/8A, Valve Cotter Tool Kit - Guide Plate 29VAS5161/29 and Valve Cotter Tool Kit - Guide Plate 29-1VAS5161/29-1

Procedure

Fig 1: Identifying Valve Stem Seal

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-- Remove all glow plugs. Refer to GLOW PLUGS .

-- Remove the camshafts. Refer to CAMSHAFTS, REMOVING, USED CAMSHAFTS FOR CYLINDER BANK 1 (RIGHT), REINSTALLING .

-- 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.

-- Set the piston for the respective cylinder to the "Bottom Dead Center (BDC) position".

-- Place the Valve Cotter Tool Kit - Guide Plate 29VAS5161/29 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 - PunchVAS5161/3A in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- Install the Valve Cotter Tool Kit - Sealing PinVAS5161/29-1 in the guide plate.

Fig 3: Identifying Sealing Pin VAS 5161/29-1

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-- Install the Valve Cotter Tool Kit - AdapterVAS5161/11 hand tight in the glow plug threads.

-- Install the Valve Cotter Tool Kit - RetainerVAS5161/6 with the Valve Cotter Tool Kit - Threaded Studs VAS5161/5 in the guide plate.

Fig 4: 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.

-- Connect the adapter to the compressed air using a commercially available intermediate piece and give steady pressure.

• Minimum pressure: 6 bar (87 psi)

-- Engage the Valve Cotter Tool Kit - Pressure Fork VAS5161/2 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 5: Identifying Puller - Valve Seal 3364

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If puller cannot be used on several valve stem seals due to restricted clearance, proceed as follows:

-- Remove the roll pin -arrow- on the puller with a drift and remove the impact puller attachment.

Fig 6: Driving Out Roll Pin

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-- Position the lower part of the Puller - Valve Seal3364 on the valve stem seal.

Fig 7: Identifying Puller - Valve Seal 3364

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-- Secure the puller with a drift or cotter pin drive -1- as shown in the illustration.

-- Position the valve lever on the puller and remove the valve stem seal -arrow-.

Fig 8: 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 Insertion DeviceVAS5161/18.

Fig 9: 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 10: 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

Assemble in reverse order of disassembling. Note the following:

-- Install the camshafts. Refer to CAMSHAFTS, REMOVING, USED CAMSHAFTS FOR CYLINDER BANK 1 (RIGHT), REINSTALLING .

-- Install the glow plugs. Refer to GLOW PLUGS .