Valve Stem Seals, Removing And Installing, Cylinder Head Installed

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 .