Replacing Valve-Stem Seals (Cylinder Head Installed)

NOTIFICATION 

Engine damage 

• Risk of damage to valves due to incorrect handling 
  1. → To prevent the valve from falling into the cylinder, the guide plate and sealing pins must not be unscrewed.
  2. → Overpressure in the cylinder must be kept at at least 6 bar.
  3. → Cover passages and openings from the cylinder head into the crankcase.

1. Position the pistons of the relevant cylinder at the bottom dead centre. 
2. VAS 5161/19C - Guide plate-1-  must be aligned using the knurled screws VAS 5161/12 -2-  on the cylinder head above the respective combustion chamber and then tightened.

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   Guide plate

3. T40012 - Adapter-1-  must be screwed into the spark plug thread.
   1. 3.1  Connect compressed air with minimum pressure  of 6 bar to the T40012 - adapter.-1- 
   2. 3.2  Loosen any tight valve keys using punch VAS 5161/3 -2-  and a plastic hammer.
   3. 3.3 Punch VAS 5161/3 -2-  must be removed.

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   Fit adapter

   Information 

   The knurled screw slips as far as it can go into the assembly cartridge VAS 5161/8  when picking up the valve keys.

4. Remove valve keys using assembly cartridge VAS 5161/8 -3- 
   1. 4.1  Screw retainer VAS 5161/6 -1-  with attachment fork VAS 5161/5 -2-  into the centre thread of the VAS 5161/19C - guide plate. 
   2. 4.2  Insert assembly cartridge VAS 5161/8 -3-  into the VAS 5161/19C - guide plate. 
   3. 4.3  Engage pressure fork VAS 5161/2 -4-  on the retainer VAS 5161/6 -1- 
   4. 4.4  Press assembly cartridge VAS 5161/8 -3-  down using pressure fork VAS 5161/2 -4-  and turn the knurled screw on the assembly cartridge to the right at the same time until the tips engage in the valve collets.
   5. 4.4.1  Turn the knurled screw back and forth slightly to press the valve keys apart and engage them in the assembly cartridge VAS 5161/8 -3- 
   6. 4.5  Relieve pressure on pressure fork VAS 5161/2 -4-  and remove assembly cartridge VAS 5161/8 -3- 
      1. 4.5.1  Remove valve keys from the assembly cartridge VAS 5161/8 -3- 

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   Retainer

5. Remove valve-spring plates and valve springs.
   1. 5.1  Mark the installation position of the valve springs and valve-spring plates for re-installation.
   2. 5.2  Set the valve springs and valve spring plates down on a suitable surface so that they cannot get mixed up and are ready for re-installation.
6. Pull off valve-stem seals using 3364 - puller.-1- 

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   Puller

7. Install new valve-stem seals. -4- 
   1. 7.1  Push assembly sleeve -3-  onto the valve stem. -2- 
   2. 7.2  Lightly oil the sealing lip on the valve-stem seal. -4- 
   3. 7.3  Insert valve-stem seal -4-  into the 3365 - valve stem seal fitting tool-5-  and press it carefully over the assembly sleeve -3-  as far as it will go onto the valve guide. -1- 
   4. 7.4  Remove assembly sleeve. -3- 

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   Installing valve-stem seal

8. Pick up valve keys using assembly cartridge VAS 5161/8. 
   1. 8.1  Insert valve keys into the insertion device VAS 5161/18 -1- 
      1. 8.1.1  Press spring washer of the insertion device VAS 5161/18 -1-  downwards and insert the valve keys with the narrow end pointing downwards.
   2. 8.2  Press assembly cartridge VAS 5161/8  onto the valve keys from above and pick up the valve keys.

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   Insertion device

9. Install valve springs and valve-spring plates.
   1. 9.1  Assign and install valve springs and valve-spring plates according to the markings made during removal.
10. Install valve keys using assembly cartridge VAS 5161/8 -3- 
    1. 10.1  Insert assembly cartridge VAS 5161/8 -3-  into VAS 5161/19C - guide plate  .
    2. 10.2  Engage pressure fork VAS 5161/2 -4-  on the retainer VAS 5161/6 -1- 
    3. 10.3  Press assembly cartridge VAS 5161/8 -3-  down using pressure fork VAS 5161/2 -4-  and pull the knurled screw on the assembly cartridge VAS 5161/8 -3-  up by screwing it to the left and right. This installs the valve keys.
    4. 10.4  Relieve pressure on pressure fork VAS 5161/2 -4-  whilst pulling on the knurled screw.
    5. 10.5  Check that all valve keys are fitted correctly.

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    Retainer

11. When all valves are secured again, disconnect the compressed air connection from T40012 - adapter  and unscrew T40012 - adapter  .
12. Repeat the procedure on all cylinders.
13. Remove tools from the cylinder head.