Valve Guide Seal: Service and Repair
Valve Stem Seals
Special tools, testers and auxiliary items required
• Spark plug removal tool (3122 B)
• Valve seal removal tool (3364)
• Valve stem seal driver (3365)
• Valve cotter disassembly and assembly device (VAS 5161)
• Adapter (T40012)
Procedure
- Remove engine. Refer to: Vehicles with manual transmission => [ Engine, Manual Transmission, Removing ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Removing ] Engine, Automatic Transmission, Removing and Installing.
- Remove camshaft timing chains from camshafts. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.
- Remove camshafts. Refer to => [ Camshafts ] Service and Repair.
- Using spark plug removal tool (3122 B), remove spark plugs.
- Turn roller rocker lever upward and secure it with a rubber band.
- Place guide plate (VAS 5161/7) from valve cotter disassembly and assembly device (VAS 5161) on cylinder head.
- Secure guide plate (VAS 5161/7) with knurled screws (VAS 5161/12).
• If guide plate cannot be screwed on, drill mounting bores to approximately 0.5 mm.
- Insert drift (VAS 5161/3) into guide plate and loosen stuck valve keepers using a plastic hammer.
- Screw engaging device (VAS 5161/6) with installation forks (VAS 5161/5) into guide plate (VAS 5161/7).
- Guide installation cartridge (VAS 5161/8 ) into guide plate (VAS 5161/7).
- Install adapter (T40012) with gasket by hand into respective spark plug thread and apply constant pressure.
• Minimum pressure: 6 bar positive pressure.
- Engage pressure fork (VAS 5161/2) at engaging device (VAS 5161/6) and press down installation cartridge (VAS 5161/8).
- At the same time, turn knurled bolt of installation cartridge (VAS 5161/8) toward the right, until the points engage in the valve keepers.
- Lightly move knurled bolt back and forth, this causes the valve keys to be pressed apart and captured in the installation cartridge (VAS 5161/8).
- Release pressure fork (VAS 5161/2).
- Take out installation cartridge (VAS 5161/8 ).
- Remove guide plate (VAS 5161/7).
• Pressurized air hose remains connected
- Remove valve spring with valve spring plate.
- Remove valve stem oil seals using Valve Seal Removal Tool (3364).
• For pressing on valve stem seals from delivery program, the Valve Stem Seal Driver (3365) must be drilled to 10.5 mm dia.
• A plastic sleeve - A - is supplied with the new valve shaft seals.
- Place plastic sleeve - A - on valve stem to prevent damage to new valve stem seals - B -.
- Lightly coat sealing lips of valve stem seal with oil.
- Push valve stem seal onto plastic sleeve.
- Carefully press valve stem oil seal onto valve guide using valve stem seal driver (3365).
- Remove plastic sleeve again.
- If the valve keepers were removed from the Installation Cartridge (VAS 5161/8), they must then be inserted into the Insertion Device (VAS 5161/18).
• The large diameter of the valve keepers points upward.
- Insert valve spring and valve spring plate.
- Install Guide Plate (VAS 5161/7) onto cylinder head again.
- Insert installation cartridge (VAS 5161/8 ) into guide plate (VAS 5161/7).
- Press down Pressure Fork (VAS 5161/2) and pull knurled bolt upward - the valve keepers are inserted in this manner.
- Release pressure fork (VAS 5161/2) with the knurled bolt still pulled.
- Install sparks plugs.
- Install camshafts. Refer to => [ Camshafts ] Service and Repair.
- Install camshaft timing chains. Refer to => [ Installing ] Camshaft Timing Chain.
- Install engine. Refer to: Vehicles with manual transmission => [ Engine, Installing ] Engine, Manual Transmission, Removing, vehicles with automatic transmission => [ Engine, Installing ] Engine, Automatic Transmission, Removing and Installing.
• After installing camshafts, do not crank engine for at least 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons).
• After working on the valvetrain and lifters, carefully rotate the crankshaft by hand at least 2 full revolutions before starting to be sure that valves do not strike the pistons.