Cylinder Head Removed: Procedure

• Mark the allocation of the roller rocker lever and the hydraulic lifter so they can be installed again.
• Remove the roller rocker lever with the hydraulic lifter and place them on a clean surface.
• If necessary, remove the intake manifold with the fuel rail. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .
• If necessary, remove the turbocharger. Refer to TURBOCHARGER, REMOVING AND INSTALLING .
• Insert the -VAS6419- in the -VAS6095A-.
• Tension the cylinder head on the cylinder head tensioning device, as shown.
• Connect the cylinder head tensioning device to 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.

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• Set the -VAS5161/19B- on the cylinder head.
• Secure the guide plate with the -VAS 5161/12-.

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• Insert the -VAS5161/3A- into the guide plate and loosen the stuck valve retainers with a plastic mallet.

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• Install the -VAS5161/6- with the -VAS5161/5- in the guide plate.
• Push the -VAS5161/8- into guide plate.

Intake Side: 

• Engage the pressure fork -VAS5161/2- on the engaging device as illustrated.

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Exhaust Side: 

• Install the -VAS5161/6- with the -VAS5161/5- in the outer threads of the -VAS5161A/19B-.

Continuation: 

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• Insert the -VAS5161/8A- into the -VAS5161/19B-.
• Engage the -VAS5161/2- on the -VAS5161/6-.
• Press down the -VAS5161/8A- and at the same time turn the knurled thumb screw on the -VAS5161/8A- to the right until the points engage in the valve retainers.
• Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.
• Release the -VAS5161/2-.
• Remove the -VAS5161/8A-.
• Remove the valve stem seals using -3364-.

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• In order not to damage the valve stem seal -4- during installation, mount the Mounting Sleeve -3- on the valve stem -2-.

• Lightly oil the valve stem seal sealing lip.

• Depending on the version/manufacturer of the valve stem seal, use the -3365- or -T40376/1-

• Insert the valve stem seal in the Seal Installer - Valve Stem -5- and carefully press on over the Mounting Sleeve on the valve guide -1- all the way.
• Remove the Mounting Sleeve.
• Insert the valve spring and valve spring retainer.
• Install the -VAS5161A- as shown.

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Intake Side: 

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Exhaust Side: 

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Continuation: 

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• If the valve retainers were removed from the assembly cartridge, they must then be inserted into the -VAS5161/18-.

• Press the -VAS5161/8- down with the -VAS5161/2- and rotate the cartridge knurled thumb screw back and forth while pulling up.
• Release the -VAS5161/2- with the knurled thumb screw pulled.
• Remove the -VAS5161A-.