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Valve stem seals

Valve stem seals

(in-car)

To remove


(This method can also be used when changing valve springs, valve discs or tappets.)


1. Remove the camshaft, see .

2. Vacuum up any oil on top of the cylinder head.

3. Detach the air hose from the intake manifold, bend it to one side and seal it.

4. Disconnect all the cables connected to the wiring harness channel and cut the securing points. Remove the channel from the cylinder head and place it on the engine.

5. Pull off the vacuum hose from the EGR valve.

6. Note the position of the fuel rails and their clamps, and mark the rails.


7. Remove the fuel return hoses from the cylinder head.

8. Remove the fuel rails (the clamps can be removed if necessary).

9. Slightly loosen the fuel connections to the fuel pump.

10. Remove the upper part of the intake manifold and seal the passageways.


11. Remove the bolts on the fuel bridges and pull out the fuel bridges from the cylinder head.

12. Fit fixing tool 83 95 444 over the injectors.

13. Lift out the valve tappets with tool 83 91 401.


14. Fit plastic sleeves 83 95 022 around the valve springs to protect the valve tappet sealing surfaces. Note the position of the sleeve.

15. Rotate the crankshaft so that the piston in the relevant cylinder is at top dead centre.

16. Engage 1st gear and apply the handbrake.

17. Unscrew the glow plug from the relevant cylinder and fit adapter 83 95 345 and air coupling 83 95 501.

Warning

The compressed air must be turned on very gradually.


Connect the compressed air and carefully pressurize the piston and valves.

18. Fit valve compressor 83 95 246 onto the cylinder head. Press down the lever and remove the valve cones.


19. Lift out the spring disc and valve spring, and remove the valve guide seals with pliers 83 94 157.


To fit


(This method can also be used when changing valve springs, valve discs or tappets.)


1. Remove the shaft of tool 83 95 071 and place the valve guide seal in the end of the tool marked “24V” with the rubber flange facing inwards (upwards on the valve stem). Fit the seal on the valve. Using a plastic mallet, carefully tap the seal into place.

2. Fit the spring and spring disc, and place the valve cones in the groove on the spring disc. Press down the lever on the valve compressor and position the valve cones. Remove the valve compressor.

3. Disconnect the compressed air and remove the air nipple.


4. Rotate the crankshaft to the 0-mark.

5. Fit the glow plugs.

Tightening torque: 10 Nm (7.5 lbf ft).

6. Remove the protective sleeves and fit the valve tappets.

7. Remove the fixing tools and fit new seals on the injector connections in the cylinder head. Remove any remains of old seals.


8. Fit new O-rings on the fuel bridges, lubricate the O-rings with acid-free vaseline and slide the fuel bridges into the cylinder head.

9. Tighten the fuel bridge bolts firmly by hand and then a further 1 turn.

10. Clean the sealing surfaces.

11. Fit a new gasket on the lower part of the intake manifold and fit the upper part.

Tightening torque: 22 Nm (16 lbf ft).

12. Fit the pressure sensor and EGR valve if the intake manifold has been changed.

13. Tighten the fuel lines on the fuel pump.


Tightening torque: 25 Nm (18.5 lbf ft).

14. Check the fuel rail connecting cones and replace if necessary.

15. Attach the fuel rails with clamps in their original positions.

Tightening torque: 25 Nm (18.5 lbf ft).

16. Check the condition of the fuel return hoses and joints and replace if necessary.

17. Connect the fuel return hoses to the fuel bridges. Pull off the connection on the fuel pump and connect pressure/vacuum pump 30 14 883. Pump up a vacuum of 750 mbar and wait for 1 minute. Make sure the dial on the tool has not moved.

If a leak is detected, the fuel bridges must be inspected individually. Remove the fuel bridge with the leak, change the seal and refit the fuel bridge. Make sure there are no more leaks.

18. Connect the vacuum hose to the EGR valve.


19. Fit the wiring harness channel to the engine and connect the wiring harness.

20. Secure the wiring harness as it was previously.

21. Refit the hose on the intake manifold.

22. Fit the camshaft, see .