SEAT Workshop Service and Repair Manuals

Replacing valve shaft seals. Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Extension and socket -3220-, see equivalent → Anchor

t	Extractor -3364-, see equivalent → Anchor

t	Pressure tool -3365-, see equivalent → Anchor

t	Valve installation kit -VAS 5161- with guide plate -VAS 5161/23- and knurled spacer ring -VAS 5161/23-1-, see equivalent → Anchor

Operation process –  Remove all glow plugs using jointed spanner -3220-. → Chapter –  Remove camshafts → Chapter. –  Set the Guide plate -VAS 5161/23- on the cylinder head as shown.

–  Secure the guide plate on the intake manifold side with the knurled screw -VAS 5161/12- and on the stud with collarless M6 nuts -1-, which are tightened manually. –  Screw the Sealing bolts -VAS 5161/10- in the guide plate.

–  Screw adapter -VAS 5161/11- into corresponding glow plug thread such that it is hand-tight.

–  Attach the Mandrel -VAS 5161/3- in the guide plate and remove the fixed wedges from the valves with a rubber hammer.

–  Screw attachment fork -VAS 5161/5- with ratchet piece -VAS 5161/6- into guide plate. –  Push knurled spacer ring -VAS 5161/23-1- onto the assembly cartridge -VAS 5161/8-. –  Connect the adapter -VAS 5161/11- to compressed air with a conventional intermediary piece and supply compressed air continuously. l  at least 6 bar –  Connect the pressure fork -VAS 5161/2- of the tool and press the assembly cartridge downwards. –  At the same time, turn the knurled screw of assembly cartridge to the right until the tips engage in valve collets. –  To disengage the cotter from the valves, move the knurled screw a little and mount the cotter in the assembly cartridge. –  Release the pressure prong. –  Remove the assembly cartridge with a knurled spacer ring, valve head and valve spring.

–  Remove the valve stem seals with the appropriate extractor -3364-.   Note

A plastic sleeve -A- is included with the new valve stem oil seals. –  Fit the plastic sleeve -A- onto the valve stem to prevent damage to the new valve stem seals -B-. –  Grease the sealing lip of the valve stem seal lightly. –  Push the sealing over the plastic sleeve. –  Carefully fit the valve stem seal on the valve guide with the valve stem seal fitting tool -3365-. –  If required, strike lightly with a plastic hammer till the valve stem seal is pressed as far as possible. –  Remove the plastic sleeve again. –  Reset the valve spring and the valve head on the cylinder head.

–  If the valve cotters were removed from the assembly cartridge, they must be first set in the fixture -VAS 5161/18-.   Note Larger diameter of valve cotter pins faces upwards. –  Press the assembly cartridge onto the insertion device from above and pick up valve cotters.

–  Set the assembly cartridge -VAS 5161/8- again in the guide plate. –  Lower the pressure fork and pull towards the knurled screw and at the same time turn towards the left and right. With this the valve cotters are set. –  Release the pressure fork with the knurled screw still in the pulled position. Installation is carried out in the reverse order; noting the following in the process: –  Install glow plugs → Chapter. –  Install camshafts → Chapter.   Note t  After installing cam shaft do not start engine for approx. 30 minutes. Hydraulic compensation elements must be set. (Else the valves fit on the pistons). t  After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.