Disconnecting Components When Replacing Valve Stem Seals

Disconnect battery lead





Disconnect battery negative lead from battery.

Remove engine parts
Remove





- the front two fuel lines clamps and lift up and place fuel rail with injector to one side. Use holder 999 5533 for injectors. Also required from model year 1995, holder 999 5620
- the two ground strips from engine
- cover over the control pulley
- charge air pipe over engine. (only Turbocharged (TC) engines). Cover Turbocharger (TC) connections.
- cover over ignition cables.

Removing timing belt





- Lift up expansion tank and place on top of engine.
- Remove front and upper timing covers.
- Remove tensioner damping unit upper screw. Slacken off the lower screw.
- Turn the tensioner damping unit so that the pulley comes free.
- Remove lower screw, tensioner damping unit.
- Remove the timing belt.

Lock tensioner damping unit





Check that there is no visible leakage.
Compress the tensioner damping unit with tool 999 5456.
Position heater pad in tool and screw tool center nut to the bottom.
Wait until compression has occurred and install a lock pin (2 mm) in the piston.

Note! If there is leakage or no resistance when pushed in or if it cannot be pushed in the tensioner damping unit must be replaced.





Mark up camshaft pulleys - both intake and exhaust.
Remove camshaft pulleys. Use counterhold 999 5199.
Reinstall expansion tank.


Removing engine components





Remove Turbocharger (TC) control valve (if present) from Air Cleaner (ACL) housing.

Remove
- Air Cleaner (ACL) housing assembly with intake manifold and hoses
- distributor cap including ignition cables and rotor
- Camshaft Position Sensor (CMP) and trigger wheel.
Disconnect torque rod and move to one side.

Remove
- torque control arm
- spark plugs

Cover spark plug wells.
Disconnect starter motor and put to one side.
Remove blind cover plug for crankshaft adjustment tool hole.

Remove camshaft cover





Install tool 999 5454 with 2-3 mm (3/32") clearance to camshaft cover. Ensure that the screw in the spark plug well is tightened as far as it will go.
Remove all screws holding camshaft cover.

Remove





- camshaft cover with pliers 999 5670 at stop lugs. Start with cylinder 1 and work alternately backward.
- wing nuts approximately 2 turns. Repeat the procedure with pliers.

Remove
- tools 999 5454
- camshaft cover





Lift out camshafts and tappets (valve depressors).
Mark up components so that they can be reinstalled in their original positions

Clean cylinder head and camshaft cover





Clean cylinder head upper sealing surface and camshaft cover lower sealing surface.
Use gasket solution 116 1440.

Note! Use a razor blade or a plastic scraper. If gasket solution is used, fume hood or extractor must be used.

Install special tool





Install press tool 999 5671 and align it along the engine.
Screw tool into place in camshaft cover corner screws.
Screw Air-bleed nipple into place 999 5672 in cylinder 1.





Align compression screw on press tool 999 5671 and attachment claw 951 2051 (4 valve) or 951 2052 (2 valve) inline with valve stem.





Set cylinder 1 to upper dead center.
Connect compressed air, 5 - 8 bar (500 - 800 kPa) (72 - 116 psi).
Press valve springs together approximately 2 turns on compression screw after valve spring compression has begun.

Note! Do not compress more than is absolutely necessary or damage may be caused to the valve stem seals.

Remove
- valve lock. Unscrew compression screw
- valve spring washer, valve spring.

Remove valve stem seals





Remove valve stem seal with tool 999 5219 taking the utmost care with tappet face.