Remove/install valve springs and valve stem seals

AR05.30-G-3510-02DD

Remove/install valve springs and valve stem seals

 Danger

Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.

Remove any sources of ignition.
Protective clothing, safety gloves and safety glasses must always be worn.
Ensure that the work area is adequately ventilated.
When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.

AS00.00-Z-0018-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A



Exhaust valve spring, exhaust valve and exhaust valve seat ring modified

BT05.30-N-0004-01RH

Engine

900.91/92 in model 000.001

Engine

902.91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.90/93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

Remove

1

Place cylinder head on a flat surface.

 The nozzle holder assembly must have been removed.

2

 Place assembly cartridge guide (8) onto cylinder head and secure with screw/bolt  provided.

3

 Screw detent part (10) into  assembly cartridge guide (8).

4

Loosen conical valve keepers (3) by gently tapping with  punch-in drift on valve spring retainer (4).

5

 Insert assembly cartridge (9) into  assembly cartridge guide (8).

6

 Hook the thrust fork (11) with attached  extension onto  the grid part (10) and place the  assembly sleeve (9).

7

 Push thrust fork (11) slightly downwards (C) until the  screw/bolt (9.1) sits below with slight pressure.

8

 Turn knurled screw (9.1) in a clockwise direction (A) until the internal cone points are tangibly latched in between the valve locks (3).

9

 Push thrust fork (11) downwards and through (C) and in doing so  bring through the screw/bolt (9.1).

 During this process the valve locks (3) are pressed into the  assembly cartridge (9) and removed.

10

 Carefully move thrust fork (11) upwards and release the tension on valve springs (5).

 The  assembly cartridge (9) is pressed upwards via valve springs (5).

11

 Unclip thrust fork (11) at  detent part (10) and remove.

12

 Take assembly cartridge (9) out of  assembly cartridge guide (8).

 Valve locks (3) remain in  assembly cartridge (9).

13

Remove the valve spring retainer (4) and valve spring (5) using a  magnetic pin and check for wear.

14

Detach valve stem seal (6) using  pliers (12).

15

Clean valve guide (14) and valve stem (13) and check for damage.

If damage is detected,



Replace valve guide (14) or valve.

Install

16

Coat assembly sleeve (15) with engine oil and slide over valve stem (13).

 Use assembly sleeve (15) with the item number A 000 053 02 54.

17

Press new valve stem seal (6) through assembly sleeve (15) onto valve guide (14) and carefully strike with  punch-in drift (16) until valve stem seal (6) sits level.

18

Remove assembly sleeve (15).

19

Check valve stem seal (6) for damage.

If damage is detected,



Replace valve stem seal (6).

20

Insert valve spring (5) and valve spring retainer (4) into  assembly cartridge guide (8).

21

 Insert assembly cartridge (9) into  assembly cartridge guide (8).

 The valve locks (3) are clipped into  assembly cartridge (9).

22

 Hook the thrust fork (11) with attached  extension onto  the grid part (10) and place the  assembly sleeve (9).

23

 Push thrust fork (11) downwards and through (C), hold it in this position, and  guide the screw/bolt (9.1) through.

24

 Pull out screw/bolt (9.1) upwards (D) from the  assembly cartridge (9).

 By pulling out  screw/bolt (9.1), the valve locks (3) fall down and out of the  assembly cartridge (9), between the valve spring retainers (4) and the valve stem end.

25

 Carefully move thrust fork (11) upwards until the valve locks (3) engage in the valve stem end.

26

 Remove thrust fork (11).

27

 Remove assembly cartridge (9).

28

Check valve locks (3) for tight seating in the valve spring retainer (4) and on the valve.

29

Perform operation steps 2 to 28 to the remaining valve springs (5) and valve stem seals of the cylinder in the same fashion.

30

  Remove assembly cartridge guide (8) and detent part (10).