Valve Stem Seals, Cylinder Head Installed: Procedure

-- Remove all glow plugs, refer to GLOW PLUG .

-- 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.

-- Move piston for that cylinder to "bottom dead center position".

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 two 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: 

-- Install the Sealing Pin VAS 5161/29-2 in the guide plate.

-- Install the Adapter VAS 5161/11 hand tight in the glow plug threads.

-- 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 Guide Forks M6/M8 with Threaded Studs VAS 5161/5 in the guide plate.

-- Insert the Valve Cotter Tool Kit - Assembly Cartridge VAS 5161/8 with the Spacer Sleeve VAS 5161A/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 psi) positive pressure.

-- 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.

-- Insert valve spring and valve spring plate.

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

-- Insert the assembly cartridge into the guide plate Valve Cotter Tool Kit - Guide Plate 31 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.