Valve Shaft Seals, Cylinder Removed: Procedure

Conditions: 

• Intake manifold removed, refer to OVERVIEW - INTAKE MANIFOLD .
• exhaust manifold/turbocharger removed, refer to OVERVIEW - TURBOCHARGER .

-- Remove the camshaft housing, refer to Removing .

-- 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.

-- Tension the cylinder head on the cylinder head tensioning device as shown.

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

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

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

Cylinder 1, 3 and 4: 

-- Place the Valve Cotter Tool Kit - Guide Plate 31 VAS 5161A/31 on the cylinder head.

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

-- Tighten the guide plate with the Knurled Thumb Screws M6 VAS 5161/12 by hand.

• The knurled bolts position, as shown.

Cylinder 2: 

-- Place the Valve Cotter Tool Kit - Guide Plate 31 VAS 5161A/31 on the cylinder head.

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

-- Tighten the guide plate with the Knurled Thumb Screws M6 VAS 5161/12 by hand.

• The knurled bolts position, as shown

Continued for All Cylinders: 

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

-- Install the retainer VAS 5161/6 with the threaded studs VAS 5161/5 in the guide plate.

-- Insert the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8 with the Sleeve VAS 5161A/31-1 installed into the guide plate.

-- Engage the Pressure Fork VAS 5161/2 at the engaging device and press the installation cartridge downward.

-- At the same time, rotate the cartridge knurled screw right until points engage in valve retainers.

-- Move the knurled wheel left and right slightly. This presses the valve retainers apart and captures them in the cartridge.

-- Release the pressure fork.

-- Remove the installation cartridge with the sleeve.

-- Remove the valve spring and the valve spring plate.

-- Remove the valve stem seal with the Puller - Valve Seal 3364.

-- Lightly oil the valve stem seal.

-- Slide the valve stem 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.

If the valve keepers were removed from the installation cartridge, they must then be inserted into the Valve Insertion Device VAS 5161/18.

• The large diameter of the valve retainers point upward.

-- Press the installation cartridge onto the insertion device for the valve retainers from above and take up valve retainers.

-- Insert valve spring and valve spring plate.

-- Insert the assembly cartridge into the Guide Plate VAS 5161A/31 again.

-- Press the pressure fork down and pull the knurled screw up while turn left and right. This inserts the valve retainers.

-- Release the pressure fork with the knurled screw still raised.

-- Repeat the procedure on each valve.