Valve Stem Seals, Removing And Installing, Cylinder Head Installed

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Special tools and workshop equipment required

Spark Plug Removal Tool: 3122B
Puller - Valve Seal: 3364
Seal Installer - Valve Stem: 3365 for valve stem seal with a simple sealing lip. Refer to Figure.
Seal Installer - Valve Stem: T40376/1 , for valve stem seal with a double sealing lip. Refer to Figure.
Valve Cotter Tool Kit - Adapter: T40012
Valve Keeper Tool Kit: VAS5161A
: VAS5161/2
: VAS5161A/3A
: VAS5161/5
: VAS5161/6
: VAS5161/8A
: VAS5161A/12
: VAS5161/19C
Mounting Sleeve. Refer to Parts Information

Procedure

-- Remove the camshafts. Refer to CAMSHAFT, 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 spark plugs using the : 3122B .

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Guide Plate, Reworking:

Fig 1: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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-- Check if the opening -arrow- is present.

-- If necessary, rework the : VAS5161/19C -arrow- until the guide plate touches the cylinder head and the guide pin -1- is free.

Continuation:

Fig 2: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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-- Tighten the : VAS5161/19C on the cylinder head as shown using the : VAS5161A/12 .

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

-- Install the : T40012 in the spark plug threads.

Fig 3: Identifying Drift VAS 5161/3 And Plastic Mallet To Loosen Stuck Valve Keepers

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-- Connect compressed air with at least 6.0 bar (87.02 psi) pressure.

-- Loosen stuck valve retainers using a : VAS5161A/3A and a plastic hammer.

Intake Side:

Fig 4: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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-- Install the : VAS5161/6 with the : VAS5161/5 in the center threads of the : VAS5161A/19C .

Exhaust Side:

Fig 5: Identifying Pressure Fork VAS 5161/2

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-- Install the : VAS5161/6 with the : VAS5161/5 in the outer threads of the : VAS5161A/19C .

Continuation:

-- Insert the : VAS5161/8A into the : VAS5161/19C .

-- 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 .

Fig 6: Identifying Valve Seal Removal Tool 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-.

Fig 7: Insert The Valve Stem Seal In The 3365
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-- 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.

-- Connect the : VAS5161A as illustrated.

Intake Side:

Fig 8: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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Exhaust Side:

Fig 9: Identifying Pressure Fork VAS 5161/2

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Continuation:

Fig 10: Identifying Installation Cartridge VAS 5161/8

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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 : VAS5161/8A onto the insertion tool from above.

-- Press the : VAS5161/8A 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 .

-- Repeat the procedure on each valve.

Assembling

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

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

-- Install the spark plugs. Refer to OVERVIEW - IGNITION SYSTEM .