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  for the valve stem seal with a single sealing lip. Refer to Figure.
  Fig 2: Identifying Seal Installer - Valve Stem 3365

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• Fitting Tool:T40376/1  for the valve stem seal with a double sealing lip. Refer to Figure.
  Fig 3: Exhaust side: Fitting Tool

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• Valve Keeper Tool Kit:VAS 5161A  with Guide Plate:VAS 5161/19C 
  Fig 4: Valve Keeper Tool Kit VAS5161A

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• Engine and Gearbox Bracket:VAS 6095A 
  Fig 5: Engine And Transmission Holder

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• Cylinder Head Tensioning Device:VAS 6419 
  Fig 6: Cylinder Head Tensioning Device

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• Assembly Tool:T40452 

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Procedure 

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-- Remove the intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .

-- 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.

Guide Plate, Reworking:

Fig 7: 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 Guide Plate:VAS 5161/19C  -arrow- until the guide plate touches the cylinder head and the guide pin -1- is free.

Continuation:

Fig 8: Identifying Valve Cotter Tool Kit - Guide Plate 19c VAS5161/19C

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-- Fasten the Guide Plate:VAS 5161/19C  on the cylinder head as shown using the Knurled Thumb Screws M6:VAS 5161/12  .

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

Intake Side:

Fig 9: Engaging Device VAS 5161/6

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-- Install the Retainer:VAS 5161/6  with the Guide Forks:VAS 5161/5  in the center threads of the Guide Plate:VAS 5161/19C  .

Exhaust Side:

Fig 10: Identifying Pressure Fork VAS 5161/2

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-- Install the Retainer:VAS 5161/6  with the Guide Forks:VAS 5161/5  in the outer threads on the Guide Plate:VAS 5161/19C  .

Continuation:

-- Insert the Assembly Cartridge:VAS 5161/8A  into the Guide Plate:VAS 5161/19C  .

-- Engage the Pressure Fork With Lever for Assembly Cartridge:VAS 5161/2  on the Retainer:VAS 5161/6  .

-- Press down the Valve Cotter Tool Kit - Assembly Cartridge:VAS 5161/8A  and at the same time turn the knurled thumb screw on the Valve Cotter Tool Kit - Assembly Cartridge:VAS 5161/8A  to the right until the points engage in the valve keepers.

-- Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

-- Release the Pressure Fork With Lever For Assembly Cartridge:VAS 5161/2  .

-- Remove the Assembly Cartridge:VAS 5161/8A  .

-- Remove the valve stem seals using the Puller - Valve Seal:3364  .

Fig 11: Identifying Valve Seal Removal Tool 3364

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• In order not to damage the valve stem seal -4- during installation, mount the Assembly Tool:T40452  -3- on the valve stem -2-.
  Fig 12: Insert The Valve Stem Seal In The 3365

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-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal into the seal installer -5- and carefully press it all the way onto the valve guide -1- over the Mounting Sleeve.

-- Remove the Assembly Tool.

-- Insert the valve spring and valve spring retainer.

-- Install the Valve Keeper Tool Kit:VAS 5161A  as shown.

Intake Side:

Fig 13: Engaging Device VAS 5161/6

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Exhaust Side:

Fig 14: Identifying Pressure Fork VAS 5161/2

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Continuation:

Fig 15: Identifying Installation Cartridge VAS 5161/8

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

-- Press the Valve Keeper Tool Kit Assembly Cartridge:VAS 5161/8  down with the Valve Keeper Tool Kit Pressure Fork with Lever for Assembly Cartridge:VAS 5161/2  and rotate the cartridge knurled thumb screw back and forth while pulling up.

-- Release the Pressure Fork with Lever for Assembly Cartridge:VAS 5161/2  with the knurled thumb screw pulled.

-- Remove the Valve Keeper Tool Kit:VAS 5161A  .

-- Repeat the procedure on each valve.

Assembling

-- Install the intake manifold. Refer to INTAKE MANIFOLD, REMOVING AND INSTALLING .