SEAT Workshop Service and Repair Manuals

Cylinder head: Removing and installing t  Removing → Anchor t  Fitting → Anchor t  Tightening torques → Anchor Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter

t	Tightening torque -VAG 1331-, see equivalent → Anchor

t	Tightening torque -VAG 1332-, see equivalent → Anchor

t	Collecting tray -VAS 6208-, see equivalent → Anchor

t	Wrench kit 17 mm -T10395-, see equivalent → Anchor

t	(only for vehicles ► 05.05)

t	Bracket -10 222A-, see equivalent → Anchor

t	Adapter -10 222A/1-, see equivalent → Anchor

t	Adapter -10 222A/3-, see equivalent → Anchor

t	Adapter -10 222A/10-, see equivalent → Anchor

t  Counterhold -2024A-, see equivalent → Anchor

t  Pressure pump -SAT 1390-, see equivalent → Anchor t  Bracket -T10014- (only for vehicles ► 05.05), see equivalent → Anchor   Note t  From 05.05 onwards, an improved engine mounting will be fitted that will make it unnecessary to remove and support the engine during the operations “ Toothed belt: removing, installing and tightening” → Chapter are no longer required. t  All the cable fixings that are opened or cut during removal of the cylinder head must be fitted in the same position when reinstalling the engine.   WARNING When completing any assembly work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  All the various lines (e.g. fuel, hydraulic system, active carbon filter system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring must be installed in their original positions. t  Ensure sufficient clearance from all moving or hot components.

Removing –  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards.   Note Before removing the cylinder head, extract the fuel from the tandem pump using the manual vacuum pump and accessories -V.A.G 1390- and the bleeding tank -V.A.G 1390/1- → Chapter .   Caution Observe the measures to be adopted when disconnecting the battery → Rep. Gr.27.

–  Disconnect battery earth strap -arrow- with the ignition switched off.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Remove the particulate filter for vehicles with front-wheel drive → Chapter. –  Remove the particulate filter for vehicles with four-wheel drive → Chapter. –  Remove the connecting pipe of the exhaust manifold / cooler for exhaust gas recirculation → Item. –  Unscrew the coolant hose at the rear. –  Remove the turbocharger support with the oil return pipe → Item. –  Remove the exhaust gas recirculation cooler → Chapter.   Note From 05.05 onwards, an improved engine mounting will be fitted that will make it unnecessary to remove and support the engine during the operations “ Toothed belt: removing, installing and tightening” → Chapter are no longer required. –  Remove toothed belt → Chapter. –  Remove the hub from the camshaft wheel → Chapter.

–  Unscrew nut -1- of the tension roller. –  Extract the retention tool -T10265- from the tensioning roller. –  Remove the securing bolts of the toothed belt cover at the rear -2- and -4-. –  Unscrew the bolt -3- and remove the Hall sender -G40- from the cylinder head. Only vehicles ► 05.05   Note The two rings for the suspension equipment are on the cylinder head. For this, the additional support must be fitted to the engine block in order to support the engine.

–  Tighten the bracket -T10014- to 20 Nm into the screw hole above the coolant pump. –  Lift the engine slightly using the spindle -A- until the spindle -B- is relieved. –  Remove the spindle -B- and put it aside. Continued for all vehicles

–  Unscrew the bolts for the cylinder head cover in the sequence -13 … 1-. –  Remove cylinder head cover.

–  Follow the sequence for loosening the cylinder head bolts.

–  Attach the lifting tackle -2024A- to the cylinder block.   WARNING The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-. Installing   Note t  If repairing, carefully remove any remains of gasket material from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. t  Carefully remove any remaining emery and abrasive material. t  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. t  Cylinder heads with cracks between valve seats can be re-used without shortening service life of the engine if cracks are only minor (max. 0.5 mm wide). t  Diesel cylinder heads are not to be re-worked. t  When installing a replacement cylinder head with the camshaft fitted, the contact surfaces between hydraulic tappets and cam running surfaces must be oiled after installing the cylinder head. t  The plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. t  Remove new cylinder head gasket from packaging, just before installation. t  Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks. t  Secure all hose connections with the correct hose clips (original parts) → ETKA (Electronic parts catalogue). t  After fitting a new cylinder head or cylinder head gasket, the coolant and engine oil must be changed. 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.

–  Check if the camshaft and the crankshaft are in TDC: l  No. 1 cylinder cams must point upwards -arrows-.

l  Lock the crankshaft sprocket using the crankshaft stop -T10100-. l  The markings on the toothed wheel sprocket -2- and the crankshaft stop -1- must align. The pin of the crankshaft stop must engage in the hole in the sealing flange.

–  Check whether there is a slit dowel sleeve inserted between the cylinders 1 and 2 -Arrow A- and bring this also in place, if it is available. –  Check which type of dowel sleeve is inserted between cylinders 3 and 4 -Arrow B-: Vehicles with slit dowel sleeve -arrow B-: l  One slit dowel sleeve must remain inserted. Vehicles with closed dowel sleeve -arrow B-: l  New sealant must be applied to a closed dowel sleeve as described in the following. –  Pull the closed dowel sleeve -Arrow B- out of the cylinder block and remove sealant residue.

–  Use compressed air for the dowel sleeve holes in the cylinder block -1- and in the cylinder head -3-. –  Clean the holes to a depth of 10 mm and de-grease them. –  Allow the holes of the cylinder block and the cylinder head to dry for 3 minutes and then lubricate it with sealant -D 154 103 A1- all over. –  Place the closed dowel sleeve -4-. 2 -  Cylinder head gasket All vehicles (continued):

–  Note the cylinder head identification. t  Part No. = -Arrow 1- t  Production code = -Arrow 2- (can be disregarded) t  Holes = -Arrow 3-   Note t  If the gasket or the cylinder head is replaced, fit a new gasket with the same identification. t  If components of the crankshaft mechanism are replaced, the new gasket must be selected by measuring the projection of the pistons at TDC.

–  Fit the cylinder head gasket. l  Note the dowel sleeves -arrows- on the engine block. l  Note the fitting position of the cylinder head; the marking “oben” (up) or the part number should face the cylinder head. Vehicles with small engine support: –  Fit the cylinder head.

Vehicles with large engine support: –  Attach the lifting tackle -2024A- to the cylinder block. –  Raise a little the cylinder head with the shop crane -VAS 6100-. –  Turn the cylinder head with the toothed belt tension roller threaded bolt in the rebate of the toothed belt rear protector and at the same time place the tension roller. –  Place the cylinder head on the cylinder block. All vehicles (continued): –  Fit new cylinder head bolts and tighten by hand.

–  Tighten the cylinder head in four stages using the following tightening sequence:

stage:	Tighten
I	–  Tighten using the torque wrench to 40 Nm.
II	–  Tighten using the torque wrench to 60 Nm.
III	–  Turn further with rigid spanner 90° (1/4 turn).
IV	–  Turn further with rigid spanner 90° (1/4 turn).

Note It is not necessary to retighten the cylinder head bolts following repairs.

Vehicles with small engine support: –  Screw on the engine lifting eye at the front on the cylinder head. –  Apply locking fluid to bolts -2 … 4- and tighten bolts; for locking fluid refer to → Electronic spare parts catalogue. –  Screw in stud -1-.

Vehicles with large engine support: –  Apply locking fluid to bolts -2 … 4- and tighten bolts; for locking fluid refer to → Electronic spare parts catalogue. –  Turn the nut -1- for the toothed belt tensioning roller on its stud.

All vehicles (continued): –  Fit the camshaft hub. –  Tighten the bolt -1- to 100 Nm and counterhold using the retention tool -T10051- to do this.

–  Slide the camshaft sprocket up to the hub. l  The toothed segment -arrow- at camshaft sprocket must face upwards. –  Screw in the bolts -1- without tightening them. –  Lock the camshaft using the locking pin -3359-. –  Fitting notched belt → Chapter. The remaining installation steps are carried out in reverse sequence - note the following points: –  Install vibration damper → Chapter. –  Install cylinder head cover → Chapter. –  Installing Poly-V belt → Chapter. –  Fit the oil feed tube. –  Install the front exhaust section with the particle filter → Chapter. –  Install exhaust system and align it free of stress → Chapter. –  Connect battery. Precautions → Electrical system; Rep. Gr.27. –  Check oil level . → Chapter.   Note Carry out an engine oil change if this is dirty → Booklet101. –  Fill up coolant → Chapter. –  Carry out a test drive and interrogate the fault memory → Vehicle diagnosis, testing and information system VAS 5051, Tightening torques

Component			Nm
Hall sender -G40- to the cylinder head			10 1)
Notched belt rear protection to cylinder head		M6	10 1)
		M8	25 1)
Hub to the camshaft			100
Centre section of notched belt guard to cylinder block			10 1)
Bottom section of notched belt guard to cylinder block			10 1)
Exhaust gas recirculation radiator to intake manifold			22
Turbocharger support to	Turbocharger		25
	Cylinder block		60
Oil return pipe to the turbocharger			15
EGR connecting pipe to	exhaust gas recirculation radiator		22
	Exhaust manifold		25
Front crosspiece of the vehicle to the bodywork			22
Heat shield to cylinder block			35
Ribbed belt tensioner to ancillaries bracket			23
Guide tube for the dipstick to	Oil filter bracket		10
	Attachment ring		10
Support for the oil supply pipe			10
Oil supply pipe to oil filter bracket			22
Oil pressure switch to oil filter bracket			20
Right air hose to bracket			8

1) Insert with locking fluid; locking fluid → ETKA (Electronic spare parts catalogue.