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Valve guide seals

Valve guide seals


To remove

(in holder)

(Cylinder head, camshafts and valve gear removed)


1. Fit sleeve 83 93 746 to protect the tappet guides.

2. Remove the seals from the valve guides using special pliers 83 94 157. If the guides are to be replaced, remove them and the seals together.


To fit


(in holder)

(Cylinder head, camshafts and valve gear removed)


1. Fit the seals using special tool 83 95 071. Place the seal in the tool and then insert the tool in the valve guide. If the valve is fitted, use the valve stem as a guide.

2. Tap the seal into position using a plastic mallet.



To remove


(in situ)

(The same method can also be used for the replacement of valve springs, valve heads or collets.)


1. Disconnect the electric leads and remove the ignition discharge module or cover plate and ignition cables. Undo the bolt for the crankcase breather pipe on the camshaft cover (turbo) and remove the nipple for crankcase ventilation and vacuum from the camshaft cover. Remove the camshaft cover.

2. Turn the crankshaft to the 0° mark, remove the chain tensioner and camshafts. Cover the space for the sprockets and timing chain to prevent collets and seals from falling inside.

Important

Place all valve parts in order in valve stand 83 93 787.


3. Lift out the tappets, using magnetic tool 83 91 401.

4. Fit plastic sleeves (83 93 746) over the valve springs to prevent scoring and scratching of the tappets. Note the positions of the sleeves.


5. Turn the crankshaft to bring the piston in the cylinder concerned up to the top dead centre position. Use flywheel locking segment 83 94 868 to prevent the crankshaft from turning, unscrew the spark plug from the cylinder in question and fit air nipple 83 94 173 in the spark plug hole. Connect a compressed air supply and pressurize the piston and valves.

6. Hold removal tool 83 94 181 against the valve head and in line with the valve stem. Strike the tool smartly with a hammer. This should free the collets from the valve and they will then be collected in the tool when it is removed.

7. Lift out the spring cap and valve spring. Remove the valve guide seal using special pliers 83 94 157.



To fit


(in situ)




1. Remove the shank from tool 83 95 071 and fit the valve guide seal in the tool with the rubber flange inwards (upwards on the valve stem). Fit the seal on the valve. Use a plastic mallet to tap the seal carefully into position.

2. Fit the spring and spring cap and position the collets in the groove in the spring cap. Using removal tool 83 94 181 and installing tool 83 94 207, carefully tap the collets home.


3. Disconnect the compressed air supply, remove the air nipple and the flywheel locking segment.

4. Turn the crankshaft to the 0 mark and then to 45°.

5. Fit the spark plugs.

Tightening torque: 28 Nm (20.7 lbf ft).

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


7. Fit the camshafts and bearing caps, beginning where the cams point downwards and press on the tappets. Bearing caps marked 1-5 for the inlet side, 6-10 for the exhaust side.

Tightening torque: 15 Nm (11 lbf ft).

Important

The black bolts have an oilway and should be fitted on the spark plug side.


8. Line up the marks on the camshafts with their timing marks and fit the camshaft sprockets and chain. Start with the camshaft on the inlet side. Do not tighten the bolts yet.


9. Turn the crankshaft back to the 0° mark.

10. Prepare the chain tensioner for fitting by pressing down the catch and pushing in the chain tensioner.

11. Fit the chain tensioner, using a 27 mm socket.

Tightening torque: 63 Nm (47 lbf ft).

12. Fit the plug for the chain tensioner with push rod and spring.

Tightening torque: 22 Nm (16 lbf ft).

13. Check that the chain is correctly seated in the guides. Rotate the crankshaft two complete turns and check that the timing marks on the flywheel and camshafts are still in alignment. Tighten the camshaft sprocket bolts.

Tightening torque: 63 Nm (47 lbf ft).

14. Clean the flanges of the camshaft cover, using benzine.

15. Apply soap to the open end of the camshaft cover and fit the cover, starting at the open end. Then continue all the way round, on both the inside and outside.


Tightening torque: 15 Nm (11 lbf ft).

16. Fit the nipple for crankcase ventilation and vacuum to the camshaft cover and fit the bolt for the crankcase breather pipe to the camshaft cover (turbo).


17. Fit the ignition discharge module or ignition cables and the cover plate.

Tightening torque: 11 Nm (8 lbf ft).

18. Reconnect the ignition discharge module leads.