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 Remove guide bolts of rocker arm bridge.

 Only on engine 904.9 up to engine end no. 039739 and on engine 906.9 up to engine end no. 041955

2 Place cylinder head on a flat surface

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

4 Screw the  latching part (2) into the  assembly cartridge guide (1).

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

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

7 Attach  thrust fork (4) with the fitted  extension to  latching part (2) and place onto  assembly cartridge (5).

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8 Gently press  thrust fork (4) downwards until  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).

9 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.

10 Carefully move the  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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11 Remove the  assembly cartridge (5) with removed cotters (6) from  assembly cartridge guide (1).

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

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

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

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Install

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

15 Pull the  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).

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

17 Attach  thrust fork (4) with the fitted  extension to  latching part (2) and place onto  assembly cartridge (5).

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

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

 By pulling out  knurled screw (5.1), cotters (6) fall down and out of  assembly cartridge (5), between valve spring retainers (7) and valve stem end.

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

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

22 Check for secure seating of cotters (6).

23 Repeat work steps 3 to 21 at remaining valve springs (8) of intake and exhaust valves in the same way.

 Valve springs (8) on the intake valve and exhaust valve are different.

24 Remove  assembly cartridge guide (1).

25 Refit guide bolts for rocker arm bridge.

 Only on engine 904.9 up to engine end no. 039739 and on engine 906.9 up to engine end no. 041955