Valve Stem Seals, Removing And Installing, Cylinder Head Installed: Procedure

-- Remove all glow plugs. Refer to GLOW PLUG, REMOVING AND INSTALLING .

-- Remove the 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.

-- Set the piston for the respective cylinder to "bottom dead center (BDC)".

Cylinders 1, 3 And 4 

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-- Place the :VAS5161A/31  on the cylinder head.

• The label -A- points to the turbocharger side.
• The label -E- points to the intake manifold side.

-- Tighten the guide plate with the :VAS5161/12  by hand.

• The knurled screw position, as shown

Cylinder 2 

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-- Place the :VAS5161A/31  on the cylinder head.

• The label -A- points to the turbocharger side.
• The label -E- points to the intake manifold side.

-- Tighten the guide plate with the :VAS5161/12  by hand.

• The knurled screw position, as shown

Continued For All Cylinders 

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-- Install the :VAS5161/29-2  in the guide plate.

-- Install the :VAS5161/11  hand tight in the glow plug threads.

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

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-- Install the :VAS5161/6  with the :VAS5161/5  in the guide plate.

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-- Insert the :VAS5161/8  with the :VAS5161A/31-1  installed into the guide plate.

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

• Minimum pressure: 6 bar (87.02 psi)

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

-- At the same time, turn the installation cartridge knurled bolt 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.

-- Release the pressure fork.

-- Remove the assembly cartridge with the sleeve.

-- Remove the valve spring and the valve spring retainer.

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

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-- Lightly oil the valve stem seal sealing lip.

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-- Slide the valve stem seal onto the plastic sleeve.

-- Carefully press the valve stem seal onto the valve guide with the :3365  .

-- Remove the plastic sleeve.

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

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• The large diameter of the valve retainers point upward.

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

-- Press the assembly cartridge onto the insertion tool for the valve retainers from above and remove the valve keeper.

-- Insert the assembly cartridge into the :VAS5161A/31  again.

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-- Press the pressure fork down and pull the knurled bolt 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 camshaft housing. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .

-- Install the glow plugs. Refer to GLOW PLUG, REMOVING AND INSTALLING .