SEAT Workshop Service and Repair Manuals

Removing and installing valve stem seals with cylinder head installed 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

t	Bolt M6x30 (2x)

Operation process –  Remove all glow plugs using U/J extension and socket -3220- → Chapter. –  Remove camshafts → Chapter. –  Mark original positions of roller rocker fingers and hydraulic compensation elements for reinstallation. –  Remove roller rocker fingers together with hydraulic compensation elements and put down on a clean surface. –  Set piston of appropriate cylinder to „bottom dead centre“.

–  Fit guide plate -VAS 5161/23- onto cylinder head. –  Secure guide plate on intake manifold side using knurled screw -VAS 5161/12- and screw tight with two nuts M6x30 -Pos. 1-.

–  Screw the Sealing bolts -VAS 5161/10- in the guide plate. –  Screw adapter -VAS 5161/11- hand-tight into glow plug hole of relevant cylinder.

–  Apply the punch -VAS 5161/3- to the guide plate and use plastic-headed hammer to release sticking valve cotter pins.

–  Screw the locking element -VAS 5161/6- with the coupling prong -VAS 5161/5- into the guide plate. –  Slide knurled spacer ring -VAS 5161/23-1- onto assembly cartridge -VAS 5161/8-. –  Connect adapter -VAS 5161/11- to compressed air line using a commercially available connection piece, and apply constant air pressure. l  Minimum pressure: 6 bar –  Attach pressure fork -VAS 5161/2- to snap-in device and push assembly cartridge down. –  At the same time, turn knurled screw of assembly cartridge clockwise until tips engage in valve cotters. –  Move knurled screw back and forth to press apart valve cotters and capture them in assembly cartridge. –  Release pressure fork. –  Remove assembly cartridge with knurled spacer ring. –  Remove valve spring and valve spring plate.

–  Extract the valve stem seals with the extractor -3364- .

Caution Risk of damage when installing valve stem seals. New valve stem oil seals -B- are supplied with plastic sleeve; fit plastic sleeve -A- onto valve stem. –  Lightly lubricate sealing lip of valve stem oil seal. –  Slip valve stem oil seal over plastic sleeve. –  Carefully fit the valve stem seal on the valve guide with the valve stem seal fitting tool -3365-. –  If necessary, use a plastic head hammer and tap lightly on fitting tool until valve stem oil seal is fitted to stop. –  Remove plastic sleeve. –  Insert valve spring and valve spring plate into cylinder head.

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

–  Insert the assembly cartridge back into the guide plate -VAS 5161/23-. –  Press pressure fork downwards and pull knurled screw upwards, turning it clockwise and anticlockwise. This inserts the valve cotters. –  Release pressure fork with knurled screw still in pulled position. –  Repeat procedure on each valve. Assembling Reassembly is carried out in the reverse order; note the following: –  Ensure that all roller rocker fingers contact valve stem ends correctly and are clipped into relevant hydraulic compensation elements. –  Install camshafts → Chapter. –  Install glow plugs → Chapter.