Installing New Valve-Stem Seals

Information 

• Position the pistons of the relevant cylinder at the bottom dead centre. 
• Each piston is pressed downwards as pressure builds up in the cylinder. 

Information 

• Before switching to another cylinder, the cylinder must be positioned at the bottom dead centre and supplied with compressed air (see above). 

Information 

When required, all valve-stem seals on both cylinder rows must be replaced.

Information 

Protective caps must be ordered as separate spare parts. They are reusable. They are used to protect the valve-stem seal so that it is not damaged at the valve stem end.

Information 

For better access, the assembly driver 9606/1 can be shortened by up to 5 cm from the upper side.

1. Prepare valve-stem seal -1-  , protection cap -3-  and > 9606/1 - assembly driver-2-.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Valve-stem seal with tool

2. Fit protection cap onto the end of the valve stem. > Protection cap 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Protection cap

3. Oil valve stem, protection cap and valve-stem seal. Push valve-stem seal with sealing lip upwards -1-  over the protection cap -2-  onto the valve stem. Remove protection cap.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Valve-stem seal pushed over protection cap and valve

4. Guide the > 9606/1 - Assembly driver over the valve stem and fit the valve-stem seal by hand or by tapping it lightly using the rubber hammer as far as it will go -Arrow-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tapping on valve-stem seal

5. Fit valve springs, concave washers and valve keys. To do this, place valve springs (there are two in the outlet valve in the turbo engine) on the bottom concave washer. Place top concave washer in position.

   Information 

   The mechanic must practise for use of the assembly cartridge to be effective. Some repetitions must be made to ensure that the valve keys are correctly held in place.

6. Insert valve keys into the assembly cartridge.
   1. 6.1 Press spring washer of the -1-  insertion device downwards and insert the valve keys -2-  with the narrow end pointing downwards.

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Valve keys in assembly fixture

   2. 6.2 Ensure that the valve keys fit symmetrically and are inserted as far as they will go in the tool. The spring washer automatically locks the valve keys in place.
   3. 6.3 Place the assembly cartridge -2-  onto the centre of the assembly fixture. Check installation position of the valve keys -1-  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Fitting assembly cartridge

   4. 6.4 Press the assembly cartridge against the spring force onto the assembly fixture. The knurled screw moves forward. Turn the knurled screw back and forth until the valve keys snap into place. Repeat several times if necessary. > Assembly cartridge with valve keys 

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Assembly cartridge with valve keys

   5. 6.5 Check that the valve keys are held symmetrically in place in the assembly cartridge -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Valve keys inserted

7. Place the valve key assembly cartridge onto the cylinder head (same as removal of valve) and position it on the top concave washer.
8. Press assembly cartridge with lever (assembly bar) down against the valve spring force and keep it pressed. The knurled screw moves forward. Turn the knurled screw back and forth until the valve keys snap into place > Installing valve keys  . Repeat several times if necessary.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Installing valve keys

9. When installing the valve keys, check that they are positioned correctly.
10. Replace all four valve-stem seals for a cylinder and refit valve keys. Only then fit compressed-air hose on the next cylinder and apply compressed air constantly.