SEAT Workshop Service and Repair Manuals

Cylinder head covers: removing and installing t  Removing → Anchor t  Fitting → Anchor Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required

t  Torque wrench -VAG 1331-, see equivalent → Anchor.

t  Base -3314-, see equivalent → Anchor

Removing –  Loosen the engine cover at the locations -arrows- and remove. –  Remove the sound insulation of the injector valves.

–  Pull the injector connector -A- and the common rail pressure sensor -C- off. –  Unscrew the fixing bolts of the coolant pipe -arrow- on the intake pipe and and position the pipe in front of the intake pipe.   Caution Pay particular attention not to damage the wires when removing the connections, because otherwise it would be necessary to replace the entire wiring harness. Do not press the pliers -3314- too firmly together to separate the connectors, otherwise the support sleeve may be damaged.

–  Apply the pliers -3314- with the pliers groove -arrow A- on the support sleeve -arrow B- and remove the connector from the glow plugs.

–  Unscrew the fixing nuts of the fuel return line on the intake pipe, open the clamp -arrow- and remove the line of the Common Rail.

–  Remove the connections of the fuel return line from the injectors. For this purpose, push the lugs down by applying a little pressure to the connection and remove the upper element upwards to release it.   Note Ensure cleanliness. No dirt must be allowed to enter the return lines or into the open connections on the injectors. –  Remove the whole return line and place in front of the intake pipe.

–  Separate the plug connection of the charge pressure actuator position sender -G581--arrow- on the exhaust gas turbocharger and loosen the line from the retainers.

–  Separate the connector of the regulation valve for fuel pressure -N276--arrow- . –  Remove the line routing of the common rail and lay to one side.

–  Remove the vacuum hose -1- from the cylinder head cover. –  Move electrical wiring and remaining vacuum hoses clear -arrows-.

–  Hang out the clips -arrows- and remove the upper cover of the toothed belt.

–  Loosen the breather hose -1- of the crankshaft sump from the cylinder head cover. Press-in the tab for releasing.   Note Ignore positions -2- and the -arrows-. –  Remove the pressure line between the high pressure pump and the common rail. –  Remove the high pressure line between the common rail and the injectors.

–  Unscrew the bolts-arrows- and remove the common rail. –  Remove the injectors → Chapter.

–  Slacken cylinder head cover bolts in the sequence -6 ... 1-. –  Remove bolts and take off cylinder head cover. Fitting Installation is carried out in the reverse order; note the following:   Note Renew seal for bolts if damaged. –  Manually fasten the bolts for the cylinder head cover in the sequence -1 … 6-.

–  Tighten the bolts to 9 Nm in the following order -1 ... 6-. –  Make sure that the cylinder head cover has been engaged correctly on the toothed belt guard.   Note The figure shows the gear pinion removed from the camshaft.

–  For this purpose, press the toothed belt guard against the cylinder head cover in the area of the clips -arrows-, e.g. using a screwdriver until you can hear it engaging. –  Check that enough free space is left between the hub and the toothed belt guard.. –  Install high-pressure lines → Chapter.