Valve Stem Seals, Removing And Installing, Cylinder Head Installed

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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 5161A

Fig 3: Identifying Valve Cotter Tool Kit VAS 5161A
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Compression Stud : VAS 5161/29-1
Guide Plate : VAS 5161 A/31
Sleeve : VAS 5161 A/31-1

Procedure

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

-- 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.

-- Set the piston for the respective cylinder to "bottom dead center (BDC)".

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:

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-- Install the Valve Cotter Tool Kit - Guide Plate 29-1: VAS 5161/29-1 in the guide plate.

-- Install the Valve Keeper Tool Kit - Adapter For Compressed Air Connection : VAS 5161/11 hand tight in the glow plug threads.

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

Fig 4: Identifying Valve Cotter Tool Kit - Punch

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-- 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.

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

Minimum pressure: 6 bar (87.02 psi)

-- 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 .

Fig 5: Identifying Puller - Valve Seal

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

Fig 6: Identifying Plastic Sleeve And Valve Stem Seals

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-- 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 Puller - Valve Seal: 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 .

Fig 7: Identifying Installation Cartridge VAS 5161/8

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The large diameter of the valve keepers point upward.

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

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

-- 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 .

-- Install the glow plugs. Refer to OVERVIEW - GLOW PLUG SYSTEM .