Valve Shaft Seals, With Cylinder Head Removed

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Special Tools And Workshop Equipment Required

Puller - Valve Seal 3364
Seal Installer - Valve Stem 3365
Valve Cotter Tool Kit VAS 5161A
Valve Cotter Tool Kit - Guide Plate 19c VAS 5161/19C
Engine And Transmission Holder VAS 6095
Cylinder Head Tensioning Device VAS 6419

Procedure

-- Remove the camshafts, refer to CAMSHAFT .

-- Mark the allocation of the roller rocker lever and the hydraulic adjusting elements so they can be installed again.

-- If necessary, remove the roller rocker levers with the hydraulic adjusting elements and place them on a clean surface.

-- Insert the Cylinder Head Tensioning Device VAS 6419 in the Engine And Transmission Holder VAS 6095.

Fig 1: Identifying Air Cushion With Lever

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-- Tension the cylinder head on the cylinder head tensioning device, as illustrated.

-- Connect the cylinder head tensioning device to the compressed air.

-- Slide the air cushion with the lever -arrow- under the combustion chambers onto the valve stem seal that will be removed.

-- Let enough compressed air flow into the air cushion until it contacts the valve plate.

-- Tighten the Valve Cotter Tool Kit - Guide Plate 19c VAS 5161/19C on the cylinder head as shown using the Valve Cotter Tool Kit - Knurled Thumb Screws M6 VAS 5161A/12.

Fig 2: Identifying Pressure Fork VAS 5161/12

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-- Insert the punch Valve Cotter Tool Kit - Punch VAS 5161/3A in the guide plate and loosen the stuck valve retainers with a plastic mallet.

For the intake side

Fig 3: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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-- Install the Valve Cotter Tool Kit - Retainer VAS 5161/6 with the Valve Cotter Tool Kit - Guide Forks M6/M8 with Threaded Studs VAS 5161/5 in the center threads of the Valve Cotter Tool Kit - Guide Plate 19c VAS 5161A/19C.

-- Insert the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A into the Valve Cotter Tool Kit - Guide Plate 19c VAS 5161/19C.

-- Engage the Valve Cotter Tool Kit - Pressure Fork With Lever for Assembly Cartridge VAS 5161/2 on the Valve Cotter Tool Kit - Retainer VAS 5161/6.

For the exhaust side

Fig 4: Identifying Pressure Fork VAS 5161/2

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-- Install the Valve Cotter Tool Kit - Retainer VAS 5161/6 with the Valve Cotter Tool Kit - Guide Forks M6/M8 with Threaded Studs VAS 5161/5 in the outer threads of the Valve Cotter Tool Kit - Guide Plate 19c VAS 5161A/19C.

-- Press down the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A and at the same time turn the knurled thumb screw on the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A to the right until the points engage in the valve keepers.

-- Move the knurled thumb screw back and forth slightly. This presses the valve retainers apart and captures them in the installation cartridge.

-- Release the Valve Cotter Tool Kit - Pressure Fork With Lever For Assembly Cartridge VAS 5161/2.

-- Remove the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A.

-- Remove valve stem seals using Puller - Valve Seal 3364.

Fig 5: Identifying Valve Seal Removal Tool 3364

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Install valve stem seals

Fig 6: Identifying Plastic Sleeve And Valve Stem Seals

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CAUTION:

Risk of damage when installing valve stem seals.

Place the plastic sleeve -A- that is attached to valve stem seals -B- on valve stem.

-- Lightly oil the valve stem seal.

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

-- Carefully press the valve stem seal onto the valve guide with the Seal Installer - Valve Stem 3365.

-- Remove plastic sleeve.

-- Insert the valve spring and valve spring plate.

-- Install the Valve Cotter Tool Kit VAS 5161A as illustrated.

Fig 7: Identifying Engaging Device VAS 5161/6 With Installation Forks VAS 5161/5 Installed Into Guide Plate VAS 5161/19

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Fig 8: Identifying Pressure Fork VAS 5161/2

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NOTE:

If the valve keepers were removed from the assembly cartridge, they must then be inserted into the Valve Cotter Tool Kit - Valve Insertion Device VAS 5161/18.

Fig 9: Identifying Installation Cartridge VAS 5161/8

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Press the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A onto the insertion device from above and capture the valve retainers.

-- Press the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8A down with the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS 5161/2 and rotate the cartridge Valve Cotter Tool Kit - Knurled Thumb Screws M6 VAS 5161A/12 back and forth while pulling up.

-- Release the Valve Cotter Tool Kit - Pressure Fork with Lever for Assembly Cartridge VAS 5161/2 with the Valve Cotter Tool Kit - Knurled Thumb Screws M6 VAS 5161A/12 pulled.

-- Remove the Valve Cotter Tool Kit VAS 5161A.

Assemble in reverse order of disassembly. Note the following:

-- Install the camshafts, refer to CAMSHAFT .