Remove/install valve springs

Modification notes

541 589 00 61 00

Valve tool kit

Magnetic pin

210 589 00 40 00

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Removing

1 Place cylinder head on a flat surface

2 Position the  assembly cartridge guide (1) over the valve group to be removed and tighten with  bolt (3).

3  Screw detent part (2) into  assembly cartridge guide (1).

4 Loosen cotters (6) by gently tapping with the  drift punch onto the valve spring retainer (7).

5  Insert assembly cartridge (5) into  assembly cartridge guide (1).

6  Hook thrust fork (4) with attached  extension onto  the grid part (2) and place on the  assembly sleeve (5).

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7 Gently press the  thrust fork (4) downwards until the  knurled screw (5.1) can be pressed downwards using gentle pressure.  Turn knurled screw (5.1) in a clockwise direction (arrow A) until internal cone points (arrows B) are tangibly latched in between cotters (6).

8 Push the  thrush fork (4) downwards and through and in doing so,  bring through knurled screw (5.1).

 The cotters (6) are pressed into  assembly cartridge (5) and removed.

9 Carefully move  thrust fork (4) upwards and release tension on the valve springs.

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

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10 Remove  assembly cartridge (5) with removed valve locks (6) from
 assembly cartridge guide (1).

11 Remove valve spring retainer (7) and valve spring (8) using a  magnetic pin, check for wear and replace if necessary.

12 Pull the  knurled screw (5.1) out of the  assembly cartridge (5) and remove cotters (6).

 Check valve stem end and cotters (6) for wear.

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Install

13 Insert valve spring (8) and valve spring retainer (7) into the ) assembly cartridge guide (1).

14 Pull  knurled screw (5.1) out at  assembly cartridge (5) and insert cotters (6) between internal cone points (arrows B).  Slowly relieve pressure on knurled screw (5.1).

15 Insert  assembly cartridge (5) with inserted cotters (6) into
 assembly cartridge guide (1).

16  Hook thrust fork (4) with attached  extension onto  the grid part (2) and place on the  assembly sleeve (5).

17 Press  thrust fork (4) downwards and hold, whilst doing so,
 knurled screw (5.1) must also be entrained.

18 Pull  knurled screw (5.1) up and out of  assembly cartridge (5).

 Pulling out the  knurled screw (5.1) causes the valve locks (6) to fall between the valve spring retainer (7) and the valve stem end.

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19 Carefully move  thrust fork (4) upwards until cotters (6) latch in at the valve stem end.

20 Place  thrust fork (4) to one side and  remove assembly cartridge (5).

21 Check secure seating of the cotters (6).

22 Repeat work steps 2 to 21 at the remaining valve springs (8) for the intake and exhaust valves in the same way.

 The valve springs (8) for the inlet valves and exhaust valves are different.

23  Remove assembly sleeve guide (1).