Removing and installing valve springs and valve stem seals - AR05.30-P-3510-02AO

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Drift (104 589 01 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Assembly Board (111 589 02 59 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Magnetic Rod (116 589 06 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Retaining Lock (602 589 00 40 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Pliers (606 589 00 37 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Drift (119 589 00 43 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Thrust Piece (111 589 25 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Valve Assembly Tool Case (111 589 25 61 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1015-05A	Cylinder leakage testing unit

1.1 With cylinder head removed: Bolt cylinder head onto assembly board 111 589 02 59 00 with two cylinder head bolts.
2.1 With cylinder head installed: Hold timing chain (23) on left and right cylinder heads with bolts M8x50 mm (arrow)to prevent it from jamming when the engine is cranked.

Fig 9: Holding Timing Chain On Left And Right Cylinder Heads With Bolts
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

3.1 With cylinder head installed: Turn piston of the cylinder to be repaired to the TDC position using a wrench socket.

If it is turned by the crankshaft, it must be ensured that the starting position is re-established so that colored markings on the timing chain can be used again to adjust the timing of the camshafts.

The relevant piston is in the TDC position when the vibration damper marking numbers listed in the table below align with the TDC pointer.

Fig 10: Identifying Vibration Damper Marking Numbers

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Marking number	Pistons at TDC
0	1 and 6
60	7 and 12
120	2 and 5
180	8 and 11
240	3 and 4
300	9 and 10

4.1 With cylinder head installed: Secure crankshaft with retaining lock 602 589 00 40 00 to prevent it from twisting.

Fig 11: Securing Crankshaft With Retaining Lock
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5.1 With cylinder head installed: Screw connecting hose (4) of cylinder leakage tester into spark plug bore and pressurize compression chamber (approx. 5 bar).

Fig 12: Screwing Connecting Hose Of Cylinder Leakage Tester Into Spark Plug Bore
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6 Screw joint bearing (19) into thread of camshaft bearing cover using a suitable holding fork (15) and align.

Fig 13: Screwing Joint Bearing Into Thread Of Camshaft Bearing Cover
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing valve springs on 3-groove split valve spring retainer locks or valve spring on 8mm dia. exhaust valve stems

3-groove split valve spring retainer locks installed as of engine end no. 980 016 880 up to 980 026 776 981 000 347 up to 981 005 051

Fig 14: Identifying Groove Split Valve Spring Retainer Locks
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7.1 Hook ratchet press (5) with lever handle (3) and thrust piece (7) 111 589 25 63 00 in joint bearing (19) and align.
8.1 Compress valve springs and remove split valve spring retainer locks with magnetic rod (06) 116 589 06 63 00.
If the split valve spring retainer locks are difficult to remove, pressurize the valve spring plates before removal to loosen the split valve spring retainer locks.

The valves must not rest on the piston crown otherwise they will be bent .
9.1 Remove valve spring caps and valve springs.

Fig 15: Identifying Valve Spring Caps And Valve Springs
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing valve springs on inlet/exhaust valves with 7.0 mm valve stem dia. and 1-groove split valve spring retainer locks

1-groove split valve spring retainer locks installed as of engine end no. 980 026 777 981 005 052 982 983
10.1 Insert pilot bushing (10) into bucket tappet bore.
11.1 Assemble thrust fork (6) with lever handle (3).
12.1 Insert assembly cartridge (8) into pilot bushing (10), hook thrust fork (6) into counterbearing (19) and rest on contact pin of assembly cartridge (8).
13.1 Exert gentle pressure on the thrust fork (6) and knurled screw while turning the knurled screw on the assembly cartridge (9) slowly at the same time (arrow) until the tips of the internal locating pin are felt to lock between the split valve spring retainer locks.

Fig 16: Identifying Thrust Fork And Lever Handle
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14.1 Exert gentle pressure on the knurled screw (arrow) on the assembly cartridge (8) and push down thrust fork (6) as far as the stop. (If necessary, use extension). The valves are removed automatically.
15.1 Release and remove thrust fork (6).
16.1 Remove assembly cartridge (8) with removed split valve spring retainer locks.
The split valve spring retainer locks can be left in the assembly cartridge until reinstallation, but if all valve springs or valves are to be removed, e.g. on a removed cylinder head, the split valve spring retainer locks can be removed from the assembly cartridge by pulling out the knurled screw.

Fig 17: Locating Thrust Fork
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Installation :

Insert assembly cartridge (8) with split valve spring retainer locks inside into the pilot bushing (10), hook thrust fork (6) into counterbearing (19) and rest gently on the two contact pins of the assembly cartridge (8).

Push down thrust fork (6) as far as the stop. Pull the knurled screw on the assemble cartridge (8) upwards (arrow) and simultaneously release the thrust fork (6) (this installs the split valve spring retainer locks).

Fig 18: Identifying Pilot Bushing And Hook Thrust Fork
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
17.1 Check whether the valve keys (21) are inside the assembly cartridge (8) and repeat steps 10.1 to 13.1 if necessary.
18.1 Remove pilot bushing (10).
19 Remove valve spring cap and lower valve spring.

Fig 19: Identifying Pilot Bushing And Valve Keys
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
20 Pull off valve stem seal (86) using pliers (1) 606 589 00 37 00.
21 Check surface of valve stems for roughness and burrs (visual inspection and nail test).
Replace valves with rough stem surface or burrs.
22 Check bottom valve spring plates for pitting and replace if necessary.

Fig 20: Identifying Valve Stem Seal
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
23 Fit cap (86a) (included in parts kit) on valve stem and oil thoroughly.
24 Push new valve stem seal (86) into assembly arbor (2) and press onto valve stem as far as the stop.
With assembly arbor 119 589 00 43 00 1st version, drill its inside dia. up to 7.5 mm.
25 Remove cap (86a).
Assembly arbor (2) 104 589 01 43 00 (8 mm dia., exhaust valves)

Assembly arbor (2) 119 589 00 43 00 (7 mm dia., inlet and exhaust valves)

Fig 21: Pushing Valve Stem Seal Into Assembly Arbor
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.