SEAT Workshop Service and Repair Manuals

Removing and installing cylinder head Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Adjustment tool -3070-

t	Diesel injection pump locking pin -3359- (2 pcs), see equivalent → Anchor

t	Hose clamp -T10050-, see equivalent → Anchor

t	Hose clamp -T10051-, see equivalent → Anchor

t	Extractor -T10052A-, see equivalent → Anchor

t	Socket XZN 10 -T10385-, see equivalent → Anchor

t	Torque wrench (5 - 50 Nm) -V.A.G 1331-, see equivalent → Anchor

t	Torque wrench (40 - 200 Nm) -V.A.G 1332-, see equivalent → Anchor

t	Tray -VAS 6208-, see equivalent → Anchor

Removing   Note t  Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. gr.27. –  With ignition switched off, disconnect earth cable at battery → Rep. gr.27.

–  Remove the engine cover upwards -arrows-. –  Remove air filter housing → Chapter. –  Remove battery and battery tray → Electrical system; Rep. gr.27. –  Drain coolant → Chapter. –  Remove the radiator cowl with the radiator fan -V7- and the radiator fan, right side -V177- → Chapter.

–  Remove the air hose; for this purpose, release hose clip -2- and lift the retaining clip -1-.

–  Remove the air hose; for this purpose, release hose clip -2- and lift the retaining clip -1-.

–  Unscrew bolts -1- and -3-. –  Slacken hose clip -5- at intake manifold flap motor -V157-, detach air pipe -2- but do not remove.   Note Disregard: -Pos. 4-.

–  Remove nuts -2- and bolts -3-, and detach exhaust gas recirculation pipe.   Note Disregard: -Pos. 1-.

Front-wheel drive vehicles –  Unbolt heat shield for right drive shaft -arrows-.

Vehicles with four-wheel drive –  Unscrew the insulating panel for the right half shaft from its mounting at the angular gears -arrows-. –  Remove the right-hand drive shaft → Rep. gr.40.

Continuation for all vehicles –  Remove bolts -1, 2- and banjo bolt -3-. –  Remove turbocharger support with oil return pipe.

–  Remove nuts -2-.   Note Disregard: -Pos. 1-.

–  Loosen the crankshaft housing breather hose -1- from the cylinder head cover. Press-in the tab for releasing. –  Move vacuum hoses -arrows- on air pipe clear. –  Loosen hose clip -2- and detach air pipe.

–  Unplug connector -1- at position sender for charge pressure positioner -G581-. –  Remove the vacuum hose -2- of the underpressure capsule from the turbocharger. –  Separate vacuum hose -3-. –  Remove exhaust gas temperature sender 1 -G235- → Chapter.

–  Loosen bolt -2- and remove clamp.   Note Ignore positions -1- and -3-. –  Move electrical wiring on turbocharger clear.

–  Unplug electrical connector -2- on exhaust gas pressure sensor 1 -G450-. –  Remove bolt -3- and detach exhaust gas pressure sensor 1 -G450- from bracket -arrow-. –  Remove upper bolt -1- at bracket for particulate filter and tie particulate filter to rear.   Note The installation position can vary depending on version.

–  Unplug the electrical connectors -1- at exhaust gas recirculation valve -N18- and -3- at intake manifold flap motor -V157-. –  Remove bolt -arrow- for dipstick guide tube. –  Remove bolts -2- for exhaust gas recirculation pipe.   Note Disregard: -Pos. 4-.

–  Unclip wiring harness from retainer -arrow-.

Vehicles with direct shift gearbox –  Remove coolant hoses from gearbox oil cooler, loosen hose clips -arrows- for this.

Continuation for all vehicles –  Move wiring harnesses -arrows- and electrical connector -1- clear at bracket.

–  Unscrew bolts -2-, -5- and -arrows-. –  Lay the electric lines and hoses on the left air duct pipe free using the removal lever -80 200-. –  Loosen hose clip -3- and remove left air pipe.   Note Ignore positions -1- and -4-.

–  Separate the underpressure hose -1- on the vacuum pump.   Note Ignore -arrows-.

–  Disconnect connector -2- from coolant temperature sensor -G62-. –  Slacken hose clips -arrows- and detach coolant hoses from connection.   Note Disregard item -1-.

–  Remove nut -1- and bolts -2-, detach exhaust gas recirculation pipe.

–  Unscrew oil supply line from connection on oil filter bracket. To do so, counterhold at hexagon flats with an open-end spanner and slacken union nut -3-.   Note Ignore positions -1- and -2-.

–  Remove nut -2- at retaining clip for vacuum line. –  Unscrew bolt -1-. –  Unscrew oil supply line from connection on turbocharger. To do so, counterhold at hexagon flats with an open-end spanner and slacken union nut -3-.

–  Remove bolt -arrow- securing rear cover for toothed belt. –  Remove the timing belt from the cogwheel of the camshaft → Chapter.

–  Remove thecounterholder -T10265-. –  Remove nut -1- and detach tensioning roller.   Note Disregard -arrow-.

–  Unplug electrical connector -Arrow- on Hall sensor -G40-. –  Remove cylinder head cover → Chapter

–  Remove bolts -1- and detach camshaft sprocket.

–  Counterhold using counterhold tool -T10051- and loosen bolt -1- for camshaft hub. –  Unscrew bolt approx. 2 turns.

–  Apply puller -T10052- to camshaft hub and and screw bolts -1- into hub. –  Counterhold on hexagon flats (30 mm) of puller and screw in bolt -2- to pull off camshaft hub. –  Remove hub from taper of camshaft.

–  Slacken cylinder head bolts in the sequence -1 ... 10-.   Note t  A second mechanic is required for removal of the cylinder head. t  The toothed belt tensioning roller is pulled off the stud when the cylinder head is lifted out. t  The oil return line of the turbocharger is pulled out of the support when the cylinder head is lifted out. –  Lift cylinder head at gearbox end first and guide out of toothed belt cover. Prevent toothed belt tensioning roller from falling down. –  Place cylinder head down taking care not to bend oil return line. If necessary, place a piece of wood under exhaust manifold.   Caution Risk of damage to glow plugs when putting down cylinder head. After removal, the cylinder head must not be put down on the gasket side with the glow plugs still installed, because the glow plugs project slightly beyond the gasket surface. Installing l  Specified torques → Chapter.   Caution Avoid damage to sealing surfaces. t  Carefully remove sealant residue from cylinder head and cylinder block. t  Ensure there are no scratches or scrapes caused. Avoid damage to cylinder block. No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. Risk of leaks at cylinder head gasket. t  Carefully remove any remains of sealant from the cylinder head and cylinder block. Ensure there are no scratches or scrapes caused. t  Carefully remove any remaining emery and abrasive material. t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle the gasket with care to avoid damaging the silicon layer or the ridged area of the cylinder head gasket. Avoid damage to open valves. When installing an exchange cylinder head, the plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. Avoid damage to valves and piston crowns after working on valve gear. Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.   Note t  Renew bolts tightened with specified tightening angle. t  Renew self-locking nuts as well as seals, gaskets and O-rings. t  Cylinder heads for TDI engines must not be reworked. t  When installing an exchange cylinder head, the contact surfaces between roller rocker fingers and cams must be oiled. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and the coolant in the entire cooling system. –  Before fitting cylinder head, remove crankshaft stop -T10050- and turn crankshaft against normal direction of rotation until all pistons are positioned approximately equally below „TDC“. –  Cylinder head gasket must lie with identification facing upwards.

–  To centre, screw guide pins -3070/9- into outer threaded holes on intake side.

–  Note cylinder head gasket identification: 1 -  Part No. 2 -  Holes 3 -  Ignore   Note t  If the cylinder head gasket or cylinder head have been replaced, select the new cylinder head gasket according to the number of holes on the old cylinder head gasket. t  If parts of the crankshaft assembly have been renewed, the new cylinder head gasket must be selected by measuring the piston projection at „TDC“ → Chapter. –  Place cylinder head gasket in position. l  Note position of dowel sleeves in cylinder block. l  Installation position of the cylinder head gasket: the word „top“ or the Part No. should face towards the cylinder head. –  Fit cylinder head.   Note Position tensioning roller on studs when fitting cylinder head. –  Insert 8 cylinder head bolts and screw in by hand until contact is made. –  Unscrew the guide pins -3070/9- through bolt holes in cylinder head and screw in remaining cylinder head bolts by hand until they make contact.

–  Tighten bolts in the sequence -1 ... 10- in 4 stages as follows: 1.  Tighten to 30 Nm. 2.  Tighten to 50 Nm. 3.  Turn 90° further. 4.  Turn 90° further.   Note Cylinder head bolts do not have to be torqued down again. –  Install rear cover for toothed belt, camshaft hub and sprocket → Chapter.

–  Lock the camshaft hub using the diesel injection pump locking pin -3359-.   Note Ignore positions -1- and -arrow-.

–  Lock the high pressure pump using the diesel injection pump locking pin -3359-.   Note Disregard: -Pos. 1-.

–  Turn the crankshaft in the direction of the engine rotation „TDC“ and lock using the crankshaft stop -T10050-. –  Install notched belt (adjusting valve timing) → Anchor. Perform further installation in reverse order, paying attention to the following: –  Mount the exhaust gas temperature sender 1 -G235- → Chapter. –  Install cylinder head cover → Chapter. –  Install oil supply line → Item. –  Install exhaust gas recirculation pipes → Chapter. –  Install air pipe (left-side) → Chapter. –  Install dipstick guide tube → Fig.. –  Mount the particle filter → Chapter. –  Install battery tray and battery → Rep. gr.27. –  Install air filter housing → Chapter. –  Install support for turbocharger → Chapter. –  Install air hose with plug-in connector → Anchor. –  Install radiator cowl → Chapter. –  Check oil level → Chapter.   Note Carry out an engine oil change if this is dirty → Booklet101. –  Fill up coolant → Chapter.