SEAT Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Guide pins -3070-

t	Special wrench, long reach -T10070-

t	Tensioning bolt -T10092-

t	Ball joint puller -T40010-

t	Drip tray -V.A.G 1306- or drip tray for workshop hoist -VAS 6208-

t	Torque wrench -V.A.G 1331- (5...50 Nm)

t  Torque wrench -V.A.G 1332- (40...200 Nm)

t  Spring-type clip pliers -VAS 5024A- Prerequisite l  The engine must be no more than warm to touch. Procedure –  Note safety precautions before beginning work → Chapter. –  Observe rules for cleanliness → Chapter. –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. –  With the ignition switched off, disconnect battery earth strap. –  Remove air filter → Rep. Gr.24 –  Drain coolant → Chapter.

–  Disconnect fuel supply and return pipe and cable from activated charcoal filter system solenoid valve 1 -arrows- from fuel rail.   WARNING Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. –  Unclip fuel hoses from bracket. –  Seal lines so that fuel system is not contaminated by dirt. Vehicles with engine code AJH –  Remove intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH.

–  Disconnect throttle cable at throttle valve control module cable disc and support bracket -arrows- (do not remove locating clip on support bracket). –  Remove pressure hose between secondary air pump motor and combination valve → Chapter, Removing and installing parts of the secondary air system.   Note Press buttons on hose couplings to do this. –  Pull vacuum hose off combination valve. Vehicles with engine code AWC –  Remove intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AWC.

–  Pull 6-pin connector (grey) off exhaust gas recirculation valve -N18--arrow-. –  Remove pressure hose between secondary air pump motor -V101- and combination valve → Chapter, Removing and installing parts of the secondary air system.   Note Press buttons on hose couplings to do this. –  Pull off vacuum hose from mechanical EGR valve. Continuation for all vehicles –  Remove intake manifold → Rep. Gr.24.   Note Block off intake ports in cylinder head with a clean rag.

–  Remove trim panel/air duct -1- and trim panel/battery -2-. –  Remove crankcase breather pipe.

–  Unscrew securing bolts from heat shield (on exhaust side) -arrows-.

–  Unscrew the three securing bolts -1- for turbocharger/exhaust manifold. –  Now remove lateral coolant connection from cylinder head. –  Remove toothed belt guard upper part.

–  Set camshaft toothed belt pulley to TDC No. 1 cylinder by turning crankshaft. Marking on camshaft toothed belt pulley must align with mark on cylinder head cover. –  Remove toothed belt from camshaft pulley → Chapter. –  Turn crankshaft back slightly. –  Remove ignition coils with output stages → Rep. Gr.24. –  Remove cylinder head cover.

–  Loosen cylinder head bolts using special wrench, long reach -T10070- in sequence given and then remove completely.   Note Use special wrench, long reach -T10070- for Polydrive cylinder head bolts. –  Carefully lift cylinder head off.   Note Cover turbocharger with a clean cloth so that no dirt is able to enter charge air system. Installing   Note t  There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head. t  Do not remove new cylinder head gasket from its packing until immediately before installing. t  Handle new gasket with extreme care. Damage will cause leakage. –  Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. –  Also prevent dirt and emery cloth particles from getting into coolant. –  Now carefully clean sealing surfaces of cylinder head and cylinder block. Ensure thereby that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100). –  Carefully remove metal particles, emery residue and cloths.

–  Turn crankshaft to TDC No. 1 cylinder. –  Turn crankshaft back slightly.

–  To centralize screw guide pins -3070- into holes for cylinder head bolts 8 and 10. –  Fit new cylinder head gasket. Lettering (Part No.) must be readable. –  Fit cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand. –  Remove guide pins with removal tool from guide pins -3070- through the bolt holes. To do this turn removal tool anti-clockwise, until the pins are free. –  Now insert last two cylinder head bolts and tighten them hand-tight also.

–  Tighten cylinder head bolts in tightening sequence as follows: –  Pretighten all bolts to 40 Nm. –  Then tighten all bolts 1/4 turn (90°) further using a rigid wrench. –  Then tighten all bolts again 1/4 turn (90 °) further. Further assembly is basically the reverse of the dismantling procedure. –  Install cylinder head cover. –  Install ignition coils and tighten to 10 Nm. –  Install toothed belt and adjust valve timing → Chapter. Filling with new coolant → Chapter. Vehicles with engine code AJH –  Adjusting accelerator cable → Chapter, Repairing accelerator mechanism. –  Reading and clearing fault memory → Rep. Gr.01. Vehicles with engine code AWC –  Reading and clearing fault memory → Rep. Gr.01.