Valve Stem Seals, Removing And Installing, Cylinder Head Installed: Procedure

-- Remove all the glow plugs, refer to GLOW PLUG, REMOVING AND INSTALLING .

-- Camshafts, removing:

• Refer to Removing 
• Refer to Removing 

-- 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.

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

-- Place the Valve Keeper Tool Kit - Guide Plate VAS 5161A/29 on the cylinder head.

Fig 1: Identifying Valve Keeper Tool Kit - Guide Plate VAS 5161A/29

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-- Secure the guide plate with the Knurled Screws VAS 5161/12.

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

-- Install the Sealing Pin VAS 5161/29-1 in the guide plate.

Fig 2: Identifying Sealing Pin VAS 5161/29-1

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-- Install the Adapter VAS 5161/11 hand tight in the glow plug threads.

-- Install the Retainer VAS 5161/6 with the Threaded Studs VAS 5161/5 in the guide plate.

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

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-- Insert the Installation Cartridge VAS 5161/8A 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 Pressure Fork VAS 5161/2 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 Seal 3364.

Fig 4: 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:

Fig 5: Driving Out Roll Pin

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-- Remove the roll pin -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: 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 7: 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 Stem 3365.

-- Remove plastic sleeve.

If the valve retainers were removed from the installation cartridge, they must then be inserted into the Valve Insertion Device VAS 5161/18.

Fig 8: 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 keepers.

-- Insert the cartridge into the Guide Plate VAS 5161A/29.

Fig 9: 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.