Valve Stem Seals, Removing And Installing, Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal: 3364 
  Fig 1: Identifying Puller - Valve 3364

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• Seal Installer - Valve Stem: 3365 
  Fig 2: Identifying Seal Installer - Valve Stem 3365

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• Valve Keeper Tool Kit: VAS 5161 A  with Valve Keeper Tool Kit - Guide Plate 31 : VAS 5161 A/31  and Spacer Sleeve : VAS 5161 A/31-1 
  Fig 3: Valve Keeper Tool Kit VAS5161A

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• Engine and Transmission Holder: VAS 6095A 
  Fig 4: Identifying Engine and Gearbox Bracket VAS6095A

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• Cylinder Head Tensioning Device: VAS 6419 
  Fig 5: Cylinder Head Tensioning Device

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• Mounting Sleeve. Refer to Parts Information

Procedure 

-- Remove the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- 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.

-- Remove the cylinder head. Refer to CYLINDER HEAD, REMOVING AND INSTALLING .

-- The exhaust manifold and the intake manifold must be removed from the removed cylinder head.

-- Insert the Cylinder Head Tensioning Device: VAS 6419  in the Engine and Gearbox Bracket VAS 6095A: VAS 6095A  .

-- 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.

Cylinders 1, 3 and 4: 

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-- Place the Valve Cotter Tool Kit - Guide Plate 31 : VAS 5161 A/31  on the cylinder head.

• The label -A- points to the turbocharger side.
• The label -E- points to the intake manifold side.

-- Tighten the guide plate with the Valve Keeper Tool Kit - Knurled Thumb Screws M6 : VAS 5161/12  by hand.

• The knurled screw position, as shown

Cylinder 2: 

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-- Place the Valve Cotter Tool Kit - Guide Plate 31 : VAS 5161 A/31  on the cylinder head.

• The label -A- points to the turbocharger side.
• The label -E- points to the intake manifold side.

-- Tighten the guide plate with the Valve Keeper Tool Kit - Knurled Thumb Screws M6 : VAS 5161/12  by hand.

• The knurled screw position, as shown

Continued for all cylinders: 

-- Insert the Valve Cotter Tool Kit - Punch : VAS 5161/3A  in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- Install the Valve Keeper Tool Kit - Retainer : VAS 5161/6  with the Valve Keeper Tool Kit - Guide Forks M6/M8 with Threaded Studs : VAS 5161/5  in the guide plate.

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-- Insert the Valve Cotter Tool Kit - Assembly Cartridge : VAS 5161/8  with the Sleeve : VAS 5161 A/31-1  installed into the guide plate.

-- Engage the Valve Keeper Tool Kit - Pressure Fork : VAS 5161/2  at the engaging device and press the installation cartridge downward.

-- At the same time, turn the installation cartridge knurled bolt right until points engage in the valve keepers.

-- Move the knurled bolt left and right slightly. This presses the valve keepers apart and captures them in the assembly cartridge.

-- Release the pressure fork.

-- Remove the assembly cartridge with the sleeve.

-- Remove the valve spring and the valve spring retainer.

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

-- Place the plastic sleeve -A- that is included with the new valve stem seals -B- on the valve stem.

-- Lightly oil the valve stem seal sealing lip.

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

-- Carefully press the valve stem seal -B- onto the valve guide with the Seal Installer - Valve Stem: 3365  .

-- Remove the plastic sleeve.

If the valve keepers were removed from the assembly cartridge, they must then be inserted into the Valve Keeper Tool Kit - Valve Insertion Device : VAS 5161/18  .

• The large diameter of the valve keepers point upward.

-- Press the assembly cartridge onto the insertion tool for the valve keepers from above and remove the valve keeper.

-- Insert the valve spring and the valve spring retainer.

-- Insert the assembly cartridge back into the Valve Cotter Tool Kit - Guide Plate 31 : VAS 5161 A/31  .

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

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

-- Repeat the procedure on each valve.

Assembling 

Assemble in the reverse order of removal. Note the following:

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

-- Install the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .