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. Prepare guide plate -1-  .
   1. 1.1  Screw in M8 hexagon socket head bolts with a large bolt head diameter -Arrow-  from > VAS 5161A - removal and installation device for valve cotters  on the underside of the > VAS 5161A/38 - guide plate-1-  .

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   Guide plate on cylinder head

2. Turn the crankshaft clockwise using > T40263 - wrench, a/f 21  and > T40314 - adapter  at the pulley until the piston in the relevant cylinder is at BDC  position.
3. > VAS 5161A/38 - Guide plate-1-  must now be secured to the cylinder head.
   1. 3.1  > VAS 5161A/38 - Guide plate-1-  on the cylinder head must be aligned above the relevant combustion chamber.

      Observe markings A - Outlet side/E - Intake side  while doing this.

   2. 3.2  Tighten screws -Arrows-  .
      • Tightening torque 9 Nm (6.5 ftlb.) 
   3. 3.3  Fit punch VAS 5161/3A -2-  from tool set > VAS 5161A - Removal and installation device for valve cotters  on the valve-spring plate and loosen any tight valve keys by tapping them with a plastic hammer.

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      Screws on guide plate

4. Build up overpressure in the combustion chamber.
   1. 4.1  Screw compression stud VAS 5161/10  from tool set > VAS 5161A - removal and installation device for valve cotters  hand-tight into the > VAS 5161A/38 - guide plate  .
   2. 4.2  Screw > T40012 - adapter  with sealing ring hand-tight into the guide plate.
   3. 4.3  Connect compressed air with minimum pressure of 6 bar  to the > T40012 - adapter  .

   Information 

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

5. Remove valve springs using > VAS 5161A - removal and installation device for valve cotters  .
   1. 5.1  Screw retainer VAS 5161/6  with guide fork -1-  and M8 threaded bolt VAS 5161/5  into the > VAS 5161A/38 - guide plate  . > Valve keys 
   2. 5.2  Insert assembly cartridge VAS 5161/8A -2-  into the > VAS 5161A/38 - guide plate  .
   3. 5.3  Engage pressure fork VAS 5161/2 -3-  on the retane. VAS 5161/6. 
   4. 5.4  Press assembly cartridge VAS 5161/8A -2-  down and turn the knurled screw -arrow-  on the assembly cartridge VAS 

      5161/8A -2-  to the right at the same time until the tips engage in the valve keys.

   5. 5.5  Turn the knurled screw -arrow-  back and forth to press the valve keys apart and engage them in the assembly cartridge VAS 5161/8A -2-  .

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   Valve keys

6. Relieve tension on pressure fork VAS 5161/2  and remove assembly cartridge VAS 5161/8A. 
   1. 6.1  Remove valve keys from the assembly cartridge.
7. Mark the installation position of the valve springs and valve-spring plates for re-installation.
8. Remove valve springs with valve-spring plates and set them down on a suitable surface so that they cannot get mixed up and are ready for re-installation.
9. Pull off valve-stem seals using the puller > 3364 - Valve stem seal puller-1-  .

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   Puller 3364 on cylinder head

10. Install new valve-stem seals -4-  on the intake s de
    1. 10.1  Push assembly sleeve -3-  onto the valve stem -2-  .
    2. 10.2  Lightly oil the sealing lip on the valve-stem seal -4-  .
    3. 10.3  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. 10.4  Remove assembly sleeve -3-  .

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    Installing valve-stem seal on intake side

11. Install new valve-stem seals -4-  on the outlet side
    1. 11.1  Push assembly sleeve -3-  onto the valve stem -2-  .
    2. 11.2  Coat sealing lip of the valve-stem seal -4-  with oil.
    3. 11.3  Insert valve-stem seal -4-  into the > T40376/2 - press-on tool-5-  and carefully press it over the assembly sleeve -3-  as far as it will go onto the valve guide -1-  .
    4. 11.4  Remove assembly sleeve -3-  .

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    Installing valve-stem seal on outlet side

12. Pick up valve keys using assembly cartridge VAS 5161/8A. 
    1. 12.1  Insert valve keys into the insertion device VAS 5161/18  in such a way that the large diameter of the valve keys is facing upwards.
    2. 12.2  Press assembly cartridge VAS 5161/8A  onto the valve keys from above and pick up the valve keys.
13. Install valve springs and valve-spring plates.
    1. 13.1  Assign valve springs and valve-spring plates according to the markings made during removal.
    2. 13.2  Install valve spring intake valve  with closely spaced spring coils facing down towards the cylinder head.
    3. 13.3 Valve spring in outlet valve:  Install with coloured markings facing upwards.
14. Insert assembly cartridge VAS 5161/8A  into the > VAS 5161A/38 - guide plate  .
15. Install valve keys.
    1. 15.1  Press pressure fork VAS 5161/2  down, pull knurled screw on the assembly cartridge VAS 5161/8A  upwards by turning it back and forth, thereby inserting the valve keys.
    2. 15.2  Reduce pressure on the pressure fork whilst pulling on the knurled screw.
    3. 15.3  Check that all valve keys are fitted correctly.
16. When all valves are secured again, disconnect the compressed air connection from > T40012 - adapter  and unscrew > T40012 - adapter  .
17. Repeat the procedure on all cylinders.
18. Remove tools from the cylinder head.