Valve Stem Seals, Replacing, Cylinder Head Installed

Special tools and workshop equipment required

Spark Plug Removal Tool 3122B
Puller - Valve Seal 3364
Seal Installer - Valve Stem 3365
Valve Cotter Tool Kit VAS5161 with Valve Cotter Tool Kit - Guide Plate 19C VAS5161/19C
Valve Cotter Tool Kit - Adapter T40012

Procedure

-- Remove the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

-- 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.

-- Remove the spark plugs with Spark Plug Removal Tool 3122B.

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

-- Position the Valve Cotter Tool Kit - Punch VAS5161/3A on the valve spring plate and loosen the stuck valve retainers with a plastic mallet.

Fig 1: Identifying Valve Cotter Tool Kit - Punch VAS 5161/3

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-- Place Valve Cotter Tool Kit - Guide Plate 19C VAS5161/19C from Valve Cotter Tool Kit VAS5161 on the cylinder head.

Fig 2: Placing Valve Cotter Tool Kit - Guide Plate 19C VAS 5161/19C On Cylinder Head

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-- Secure the guide plate with the Valve Cotter Tool Kit - Knurled Thumb Screws VAS5161/12.

-- Install the Valve Cotter Tool Kit - Adapter T40012 with sealing ring in the spark plug thread and tighten by hand.

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

Minimum pressure: 6 bar (87 psi)

-- Install the Valve Cotter Tool Kit - Retainer VAS5161/6 with the Valve Cotter Tool Kit - Guide Forks M6/M8 with Threaded Studs VAS5161/5 in the guide plate.

Fig 3: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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-- Push the Valve Cotter Tool Kit - Assembly Cartridge VAS5161/8A into guide plate.

-- 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 cartridge.

-- Unfasten guide plate and turn it aside.

Pressurized air hose remains connected.

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

-- Remove the valve stem seal with the Puller - Valve Seal 3364.

Fig 4: Identifying 3364

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If the Puller - Valve Seal 3364 cannot be used on several valve stem seals due to restricted clearance, proceed as follows:

Fig 5: Driving Out Roll Pin

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

-- Position the lower part of the Puller - Valve Seal 3364 on the valve stem seal.

Fig 6: Positioning 3364 Valve Stem Removal Tool At Valve Stem Oil Seal

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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 7: Identifying Plastic Sleeve And Valve Stem Seals

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CAUTION:

Risk of damage when installing valve stem seals.

Place the plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

-- 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 Stem 3365.

-- Remove plastic sleeve.

If the valve retainers were removed from the assembly cartridge, they must then be inserted into the Valve Cotter Tool Kit - Valve Insertion Device VAS5161/18.

Fig 8: Identifying Installation Cartridge VAS 5161/8

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The large diameter of the valve retainers point upward.

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

-- Insert valve spring and valve spring plate.

Installed position, valve spring. Refer to Figure.

-- Attach the Valve Cotter Tool Kit - Guide Plate 19C VAS5161/19C onto the cylinder head again.

-- Insert installation cartridge in guide plate.

-- 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.

Fig 9: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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Assembling

Assemble in reverse order of disassembling. Note the following:

-- Make sure all the roller rocker levers lie on the ends of the valve stems correctly and are clipped onto the respective hydraulic adjusting elements.

-- Install the spark plugs (30 Nm).

-- Install the camshafts. Refer to CAMSHAFT, REMOVING AND INSTALLING .

CAUTION:

Risk of damaging valves and piston heads after working on valve train.

The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.
To ensure valves do not strike pistons when starting, carefully rotate engine at least two full revolutions.