LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Mercedes Benz >> 2022 >> Sprinter 2500 Van Cargo, 2.0L Eng >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Timing >> Testing & Repair >> Remove/Install Valves - Ar05.30-D-3511TSR
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Remove/Install Valves - Ar05.30-D-3511TSR

Engine 651 in model 907 

G13786405
G13786406
CAUTION Risk of injury  to skin and eyes due to handling of engine oil. Risk of poisoning  caused by swallowing engine oil Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.
AS18.00-Z-0001-01A
  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
  Preparatory tasks     
1 Remove cylinder head (1). Model 907 AR01.30-D-5800TSR
2 Attach cylinder head (1) to assembly device (01). NOTES
Before putting SPECIAL TOOL assembly device (01) into operation, check that counterholders (02) have been correctly attached to cylinder head (1).
There is otherwise the danger that the cylinder head (1) is pressed upwards out of the SPECIAL TOOL assembly device (01) and that the cylinder head (16) or the valves (6) are damaged.
IMPORTANT Comply with the operating instructions for the SPECIAL TOOL ssembly device (01).
 
    SPECIAL TOOL Assembly tool Fig 1
3 Attach assembly lever (03) with depressor (04) to the sliding piece (05). IMPORTANT Position the SPECIAL TOOL depressor (04) vertically at upper valve spring retainer (2) and align to sliding piece (05).  
    SPECIAL TOOL Valve assembly tools kit Fig 2
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Depressor Fig 6
REMOVING Remove     
4 Move the air bellows of the assembly device (01) with the lever (06) in such a way that the air bellows is aligned above the combustion chamber with the respective valves (6). NOTES
Ensure that the air bellows for the SPECIAL TOOL assembly device (01) always correctly coincides with the combustion chamber and is pushed in the middle.
The air bellows can be pushed out of the side of the combustion chamber otherwise and this leads to damage to the valves (6).
IMPORTANT Comply with the operating instructions for the SPECIAL TOOL assembly device (01).
 
    SPECIAL TOOL Assembly tool Fig 1
5 Connect compressed air supply to assembly device (01). SPECIAL TOOL Assembly tool Fig 1
6 Open compressed air valve on assembly device (01) IMPORTANT Comply with the operating instructions for the SPECIAL TOOL assembly device (01).
Press the air bellows of the SPECIAL TOOL assembly device (01) in the combustion chamber onto the valve disks.
 
    SPECIAL TOOL Assembly tool Fig 1
7 Press together the valve spring (3) and the depressor (04) and remove the valve keepers (4) with the magnetic finger (07). SPECIAL TOOL Valve assembly tools kit Fig 2
    SPECIAL TOOL Magnetic finger Fig 3
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Depressor Fig 6
8 Remove the top valve spring retainer (2) with the valve spring (3) and bottom valve spring retainer (5).    
9 Remove valve stem seal with pliers.   AR05.30-D-3500-03TSR 
    NOTES
Detach valve stem seal using only SPECIAL TOOL pliers. Otherwise, the valve stem or the valve (6) will be damaged.
 
    SPECIAL TOOL Pliers Fig 5
10 Close compressed air valve on assembly device (01) SPECIAL TOOL Assembly tool Fig 1
11 Release pressure in the air bellows of the assembly device (01). IMPORTANT Comply with the operating instructions for the SPECIAL TOOL assembly device (01).  
    SPECIAL TOOL Assembly tool Fig 1
12 Perform the operation steps when removing further valves (6) in the same way. IMPORTANT Operation steps 4 to 11.  
13 Remove cylinder head (1) from assembly device (01) and remove valves (6). SPECIAL TOOL Assembly tool Fig 1
INSPECT Check     
14 Perform a visual inspection of all components of the valve drive. Depending on the findings,

Replace damaged components.
 
INSTALLING Install     
15 Insert valves (6) in cylinder head (1) and attach cylinder head (1) to assembly device (01). SPECIAL TOOL Assembly tool Fig 1
16 Move the air bellows of the assembly device (01) with the lever (06) in such a way that the air bellows is aligned above the combustion chamber with the respective valves (6). NOTES
Ensure that the air bellows for the SPECIAL TOOL assembly device (01) always correctly coincides with the combustion chamber and is pushed in the middle.
The air bellows can be pushed out of the side of the combustion chamber otherwise and this leads to damage to the valves (6).
IMPORTANT Comply with the operating instructions for the SPECIAL TOOL assembly device (01).
 
    SPECIAL TOOL Assembly tool Fig 1
17 Open compressed air valve on assembly device (01) IMPORTANT Comply with the operating instructions for the SPECIAL TOOL assembly device (01).
Press the air bellows of the SPECIAL TOOL assembly device (01) in the combustion chamber onto the valve disks.
 
    SPECIAL TOOL Assembly tool Fig 1
18 Install valve stem seal.   AR05.30-D-3500-03TSR 
    SPECIAL TOOL Drift Fig 4
19 Insert the top valve spring retainer (2) with the valve spring (3) and bottom valve spring retainer (5).    
20 Press together the valve spring (3) and the depressor (04) and insert the valve keepers (4) with the magnetic finger (07). SPECIAL TOOL Valve assembly tools kit Fig 2
    SPECIAL TOOL Magnetic finger Fig 3
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Depressor Fig 6
21 Close compressed air valve on assembly device (01) SPECIAL TOOL Assembly tool Fig 1
22 Release pressure in the air bellows of the assembly device (01). NOTES Comply with the operating instructions for the SPECIAL TOOL assembly device (01).  
    SPECIAL TOOL Assembly tool Fig 1
23 Perform the operation steps when installing further valves (6) in the same way. IMPORTANT Operation steps 16 to 22.  
  Final activities     
24 Disconnect compressed air supply to assembly device (01). SPECIAL TOOL Assembly tool Fig 1
25 Remove assembly lever (03) with depressor (04) from the sliding piece (05). SPECIAL TOOL Valve assembly tools kit Fig 2
    SPECIAL TOOL Assembly tool Fig 1
    SPECIAL TOOL Depressor Fig 6
26 Remove cylinder head (1) from assembly device (01). SPECIAL TOOL Assembly tool Fig 1
27 Install cylinder head (1). Model 907 AR01.30-D-5800TSR
Fig 1: Assembly Tool (271 589 00 59 00)
G13786407
Fig 2: Valve Assembly Tools Kit (111 589 25 61 00)
G13786408
Fig 3: Magnetic Finger (116 589 06 63 00)
G13786409
Fig 4: Drift (604 589 00 43 00)
G13786410
Fig 5: Pliers (606 589 00 37 00)
G13786411
Fig 6: Depressor (640 589 00 61 00)
G13786412