I have finished the engine repairs and saved around $4K in labor costs. The final cost of the parts and tools is $1483. Some of the lessons learned for any other brave souls who want to give it a go..

Final count... 4 bent exhaust valves, 9 bent inlet valves. I also replaced all the cam followers, they all showed some pitting of the face. The cams showed no wear.

The hardest part is getting the valve keepers back in place. After this, the other jobs don't seem so bad.

Get the Bentley eBahn Repair electronic manual. It has the required information. The paper service manual is not detailed enough. The eBahn online reviews complain about XP support only. eBahn does run on Windows 7, just run it in an XP Virtual Machine.

Buy the special tools needed, they are essential. You can sell them later on Ebay.

Apart from the obvious bent valves, I found the best way to check for bent valves is to fill the combustion chamber with gas and watch it drain out of the manifold ports. If a valve is bent even 0.001 it will drain the gas very quickly. Confirmed with a lathe and dial gauge.

Intake valves always bend three at a time. You cant bend one exhaust valve, both are bent.

Amazon, ECS, Blauparts and Europa generally have the best prices and lowest shipping costs.

Amazon will always have one less valve or cam follower in stock than you need.

The plastic crank case vent pipes and rubber vacuum lines will fall apart as soon as you touch them. Replace the rubber vacuum line with 4mm silicon vacuum hose. Ebay has the best prices on these items.

Use this site, there are a lot of tips available that will minimize the number of screw ups.

 

Nice work!

 

Thanks, I took to opportunity to change the radiator and heater hoses, water O-rings, injector O-rings and clean up the inside of the inlet manifold. The car runs very smoothly now, I suspect that there were a few vacuum leaks from rotted vacuum lines. The new silicon vacuum hose I used to replace the old stuff should last much longer.