Removing and installing valve springs and valve stem seals for an installed cylinder head

210 589 00 40 00

Sleeve

Magnet pin

Pliers

Valve tool case

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346 589 01 61 00

541 589 00 61 00

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 In order to remove and install valve springs the piston of the cylinder concerned must be exactly at top dead center so that the valves do not fall into the combustion chamber.

Removing

1  Place assembly cartridge guide (1) on the cylinder head.

2  Insert sleeve (2) in the  assembly cartridge guide (1) and  align assembly cartridge guide (1).

3  Tighten down assembly cartridge guide (1) using  bolt (3).

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4 Loosen the cotters (15) by gently tapping with the  drift punch onto the valve spring plate (8).

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5 Screw  latching part (4) into the  assembly cartridge guide (1).

6  Insert assembly cartridge (5) into the  sleeve (2).

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7  Hook thrust fork (6) with attached  extension on  the detent part (4) and lay on the  assembly sleeve (5).

8  Push thrust fork (6) using slight pressure downwards (arrow B) and simultaneously turn the  knurled screw (5.1) clockwise (arrow A) until the interior split tip of the  assembly cartridge (7) noticeable latches between the cotters.

9  Push thrust fork (6) downwards all the way.

 During this process the cotters are pressed into the  assembly cartridge (5) and removed.

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10 Carefully move the  thrust fork (6) upwards and release the tension on the valve springs (9).

 The  assembly cartridge (5) and the  sleeve (2) are pushed upwards by the valve spring (9).

11  Unhook thrust fork (6) on  detent part (4) and remove.

12  Remove assembly cartridge (5) with  sleeve (2) out of the  assembly cartridge guide (1).

 The cotters (7) are remain in the  assembly cartridge (5).

13 Remove the valve spring plate (8) and valve spring (9) using a  magnetic pin, check for wear.

 Replace valve spring plate (8) and valve spring (9) if necessary.

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Shown on a removed assembly cartridge guide

14 Detach valve stem seal (12) using  pliers (10).

15 Clean valve guide (13) and valve stem (11) and check for damage.

 Replace valve guide (13) if damaged.

Shown on a removed assembly cartridge guide

Installing

16  Lubricate sleeve (14) with engine oil and push over the valve stem (11).

17 Push new valve stem seal (12) onto the  sleeve (14) and push with the  drift punch (15) onto the valve guide (13). Carefully continue to punch with the  drift punch (15) until the valve stem seal (12) is sitting in a planar condition.

18  Remove drift punch (15) and  sleeve (14).

19 Check valve stem seal (12) for damage; replace damaged valve stem seal (12) of necessary.

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20 Insert valve spring (9) and valve spring retainer (8) into the assembly cartridge guide (1).

21  Insert sleeve (2) with  assembly cartridge (5) in the  assembly cartridge guide (1).

 The cotters (7) are clipped into the  assembly cartridge (5).

22  Hook thrust fork (6) with attached  extension on  the detent part (4) and lay on the  assembly sleeve (5).

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23  Press thrust fork (6) using light pressure downwards (arrow C) until the valve spring are pressed together slightly and  hold the thrust fork (6).

24  Pull knurled screw (5.1) upwards (arrow D) and hold.  Press thrust fork (6) further all the way.

 The cotters fall out of the  assembly cartridge (5) between the valve spring plate and valve stem.

25  Carefully move thrust fork (6) upwards.

 Hold the  knurled screw (5.1) in the process.

26  Remove thrust fork (6).

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27  Remove assembly cartridge (5) with  sleeve (2).

28 Check for tight seating of cotters.

29 Perform operation steps 2 to 28 on the remaining valve springs and valve stem seals on this cylinder head in the same way.

 Align  assembly cartridge guide (1) with  sleeve (2) again if necessary.

30  Remove assembly cartridge guide (1) and  detent part (4).