Valve Stem Seals, Removing And Installing, Cylinder Head Installed

Special tools and workshop equipment required 

• Puller - Valve Seal: 3364 
• Seal Installer - Valve Stem: 3365 
• Valve Cotter Tool Kit: VAS5161A  with the Valve Keeper Tool Kit - Compression Stud: VAS5161/10 
• Guide Plate: VAS5161A/43 
• Spark Plug Socket Adapter - 3/8" : VAS6919 
• Wrench - 21mm: T40263 
• Adapter: T40314 
• Mounting Sleeve. Refer to Parts Information

Procedure 

-- Remove the applicable 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.

-- Remove all spark plugs using the : VAS6919  .

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-- Turn the crankshaft using the : T40263  and : T40314  -arrow- until the pistons of the corresponding cylinder are in "bottom dead center (BDC)".

In the : VAS5161A/43  two M5x40 bolts and four holes -a, b, c, d- are present. These are used after each installation situation.

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-- Align the : VAS5161A/43  -1- on the cylinder head at the same time pay attention to the marking:

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A - Exhaust side

E - Intake side

-- Tighten the guide plate bolts -arrows- to 9 Nm.

-- Insert the : VAS5161/3A  in the guide plate and loosen the stuck valve retainers with a plastic mallet.

-- Install the : VAS5161/10  in the guide plate.

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-- Install the : VAS5161A/35  hand-tight in the respective spark plug thread.

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

• Minimum pressure: 6 bar (87.02 psi)

-- Install the Retainer : VAS5161/6  with the Guide Forks M6/M8 with Threaded Studs : VAS5161/5  in the guide plate.

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-- Insert the Assembly Cartridge : VAS5161/8A  into the opening above the valve spring that is to be removed.

-- Engage the Pressure Fork : VAS5161/2  at the engaging device and press the installation cartridge downward.

-- At the same time, turn the installation cartridge knurled bolt -arrow- right until points engage in the valve retainers.

-- Move the knurled bolt left and right slightly. This presses the valve retainers apart and captures them in the assembly cartridge.

• The knurled bolt slides all the way in the assembly cartridge.

-- Release the pressure fork.

-- Remove the assembly cartridge.

-- Remove the valve spring and the valve spring retainer and mark the installation position.

-- Remove the valve stem seal with the : 3364  .

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If the : 3364  cannot be used on some valve stem seals due to a limited amount of space, proceed as follows:

-- Remove the roll pin -arrow- on the puller with a drift and remove the impact puller attachment.

-- Position the lower section of the : 3364  on the valve stem seal.

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-- Secure the puller with the drift or pin punch -1-.

-- Position the extractor lever on the puller and remove the valve stem seal -arrow-.

• So that the valve stem seal -2- is not damaged during installation, mount the Mounting Sleeve -1- on the valve stem.

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-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal in the : 3365  and carefully press on the valve guide all the way.

-- Remove the Mounting Sleeve.

If the valve retainers were removed from the assembly cartridge, they must then be inserted into the : VAS5161/18  .

• The large diameter of the valve retainers point upward.

-- Press the cartridge from above onto the insertion device and valve retainers.

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

• Intake valve installation position. Refer to Figure.
• Exhaust valve installation position. Refer to Figure.

-- Insert the : VAS5161/8A  back into the : VAS5161A/43  .

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-- Press the pressure fork down and pull the knurled bolt -arrow- up while turning left and right. This inserts the valve retainers.

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

-- Install the camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .