SEAT Workshop Service and Repair Manuals

Cylinder head: Removing and installing (engine code BYT) Removing → Anchor 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	Assembly tool -T10352-, assembly tool -T10352/1-, see equivalency → Anchor

t	Spanner -T10355-, see equivalent → Anchor

t	Spanner -T20079A-, see equivalent → Anchor

t	counterhold -T20208-, see equivalent → Anchor

t	Counterhold -T40011-, see equivalent → Anchor

t	Extractor -T40039-, see equivalent → Anchor

Special tools and workshop equipment required

t	attachment tool -2024A- → Anchor

t	Torque wrench -V.A.G 1331-, see equivalent → Anchor.

t	Torque wrench -V.A.G 1332-, see equivalent → Anchor.

t	Workshop crane -VAS 6100-, see equivalent → Anchor

t	Engine sealing plug set -VAS 6122-, see equivalent → Anchor

t	counterhold -T10014-, see equivalent → Anchor

Removing   WARNING Injury risk! Fuel is subjected to very high pressure! t  Do not open the high-pressure section of the injection system when removing the engine. t  However, if the engine has to be removed for repair procedures which necessitate opening the high-pressure section, the fuel pressure in the high-pressure section must be reduced in a controlled manner to a residual pressure prior to opening → Chapter. –  High pressure system pressure reduction → Chapter.   WARNING The ignition must not be turned on. The fuel lines are still filled with fuel, the fuel is not under pressure any more. When opening the fuel system, wear protective goggles and clothing to prevent injuries and contact with the skin.

–  Remove the engine cover, by pulling carefully in the direction indicated by -arrows-.

–  Release the lateral clips -arrows- and remove the upper cover of the air conduit.

–  Release the clips -arrows- and remove the lower cover of the air conduit. –  Detach bottom section of air duct with air hose.

–  Unplug connector -1- from air mass meter -G70-. –  Separate the air hose -2-. –  Unscrew the bolt -4- and remove the air filter housing.   Note Disregard: -Pos. 3-. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27.

–  Release the hose clamp -2-. –  Remove bolt -4-. –  Unplug the connector -arrows- and move the cable to one side.   Note Ignore positions -1 and 3-.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure. –  Open filler cap on coolant expansion tank. –  Remove the primary exhaust pipe with catalytic converter → Chapter. –  Remove front right wheel.

–  Release the fasteners -1 and 2- to remove the central soundproofing sump.

–  Remove the right hand side soundproofing by releasing the fasteners -1, 2, 3-.

–  Remove the air conduit guard -Pos. 1 and 2-. –  Drain coolant → Chapter.

–  Unscrew bolts -1- and remove the air duct.   Note Ignore positions -2,3, 4 and the arrow-.

–  Remove bolts -arrows-. –  Detach the air conduit guard by unlocking the clips -Pos. 1 and 2-.

–  Unplug the connectors -1 and 2- and move the cable to one side -arrows-.

–  Unscrew bolts -1 and 2- and extract the turbocharger.

–  Unscrew the hollow bolt -2- and move the coolant tube to one side. –  Unscrew the bolts -1- for the oil return line. –  Unscrew the bolts -3- for the oil supply line.   Note To show the work sequence more clearly, the sequence is described for a removed engine.

–  Release the tabs by pressing, disconnect the air hose -2- and move to one side. –  Unscrew the bolts -arrows- for the air pipes. –  Detach the sump gas breather hose -1-. –  Release the hose clamp -3- and remove the air conduit.

–  Unscrew the turbocharger oil supply conduit -1-. –  Remove the oil settling tank → Chapter.

–  Disconnect the air hoses -1, 2, 3, 4, 5-. –  Unplug the connectors -3- on the ignition coils and move wiring harness clear

–  Remove ignition coils using puller -T40039-.

–  Unscrew the cap -arrow-. –  Unscrew the bolts -1 to 6- and remove the oil settling tank of the cylinder head. –  Release the vacuum pipe. –  Replace the cap.

–  Separate the pressure hose from the vacuum pump -1- and move it to one side. –  Unscrew earth connection -2-. –  Detach the connector -3- and move the cable harness to one side. –  Disconnect the coolant hoses -4 and 5-. –  Remove the coolant hose at the back of the cylinder head.

–  Unplug electrical connectors -1 ... 4-. –  Move electrical wire -5- clear. –  Detach the vacuum duct-6- to the active carbon filter.

–  Separate the electrical connectors -1- and remove them from the support. –  Unplug electrical connectors -2 ... 4-. –  Remove the vacuum duct -5-.

–  Separate the coolant hose from the intake manifold and unscrew the bolts -arrows-.

–  Remove intake manifold support (remove securing nut -1- and bolt -2-). –  Remove the oil filter with the extractor -3417-.   WARNING Injury risk! Fuel is subjected to high pressure! To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection.

–  Detach the fuel supply hose -2- pressing on the tab to release it. –  Disconnect the vacuum pipe -1- to the active carbon filter by pressing the release tab. –  Remove coolant hose -3-.

–  Pull the active carbon deposit upwards from its support -arrows- and place it over the engine.

–  Separate and push the coolant hoses to one side -arrow-.

–  Detach the connector for valve 1 of the variable valve timing -N205--1- –  Unscrew bolts -arrows- and remove camshaft control valve 1 -N205-.

–  Unscrew bolts -1 to 5- and remove timing chain cover (top).   Caution The timing valve has a left-hand thread. –  Remove the guide tube for the dip stick.   Caution The timing valve has a left-hand thread.

–  Remove the control valve with the wrench -T10352- in the -direction of the arrow-

–  Remove bolts -arrows- and detach bearing saddle.

–  Rotate the vibration damper with the wrench -T10355- to the TDC position („OT“) -arrow-. l  The notch on the vibration damper should face the mark -arrow- on the lower cover of the distribution chains.

–  Fit the counterhold -T20208- and block the camshaft turning. l  The marks of the camshafts should coincide with the marks on the counterhold -T20208-.   Note

t  When necessary, turn the intake camshaft in the -direction of arrow A- using a wrench until the markings on the camshaft and on the support tool -T20208- correspond with each other. t  This figure is used as an instruction, being a requirement that the support tool -T20208- is mounted and that the sprocket in the camshaft is not blocked.

–  Remove sealing plug -arrow-.

–  Use an appropriate screwdriver to raise the cotter pin holding the chain tensioner in the -direction of arrow 1-, turn the crankshaft in the opposite direction to engine movement in the -direction of arrow 2- to compress the chain tensioner and fasten it with a clamp -T40011-. –  Remove the guide pin → Item and leave the distribution chain tension rail (black) supported → Item   Note Inlet camshaft will move in direction of engine rotation.

–  Remove bolt -1- and detach tensioning rail -2- downwards. –  Use screwdriver to release catch and press off top guide rail -3- forwards.   Note You must take the precaution of positioning the distribution chain in the guide of the lower cover so that it is accessible during assembly. –  Remove the distribution chain from the camshaft sprockets.

–  Extract the caps -arrows- turning them 90° anti-clockwise, in the -direction of the arrow-.   Caution Danger of damaging valves, piston crowns and bottom cover on timing chain. t  Once the camshaft chain has been extracted from the cylinder head, the crankshaft must not turn. t  Sheet metal elements which prevent the chain from falling down are located on the bottom protection element for the timing chain. If the crankshaft is turned with the chain loose, these sheet metal elements can be deformed.

–  Remove bolts -arrows-. –  Unscrew cylinder head bolts with wrench -T20079A- in sequence-1 … 5- .   Note t  If necessary, use spanner to turn camshafts before removing cylinder head bolts. t  Make sure all hoses/pipes and wiring on component are removed. t  Make sure tensioning rail and guide rail are not damaged when lifting off cylinder head.

–  Install holder -T10014- with two small and two large, as shown in figure.    -1- M8 washer, small    -2- M8 washer, large The outer diameter of the washer must be larger than the hole in the holder.    -3- M8 x 30 bolt –  Attach holding device -2024A- to holder -T10014- and to suspension eye at front left of cylinder head.

–  Hook holding device -2024A- ontoworkshop crane -VAS 6100- and lift cylinder head slightly.   Caution t  Lift cylinder head carefully until the slide rail for the camshaft timing chain is free. t  Do not damage tensioning and sliding rails under any circumstances. –  Remove the cylinder head. –  Place the cylinder head onto a soft surface (foam material). Installing Installation is carried out in the reverse order, noting the following: l  Tightening 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. Ensure that cylinder head gasket seals properly: 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. t  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. t  Turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.   Note t  Renew the bolts tightened with specified tightening angle. t  Renew seals, gaskets and self-locking nuts. t  The different cylinder head gaskets of the engine must be considered. t  Note the different sealants for sealing surfaces and cylinder head bolts. t  Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and coolant.

–  Check that the crankshaft is in TDC („OT“) -arrow-. l  The notch on the vibration damper should face the mark -arrow- on the lower cover of the distribution chains.

–  If it has been removed, fit the counterhold -T20208- and block the camshaft turning. l  The marks of the camshafts should coincide with the marks on the counterhold -T20208-.   Note

t  When necessary, turn the intake camshaft in the -direction of arrow A- using a wrench until the markings on the camshaft and on the support tool -T20208- correspond with each other. t  This figure is used as an instruction, being a requirement that the support tool -T20208- is mounted and that the sprocket in the camshaft is not blocked.

–  Place cylinder head gasket in position. t  Note position of centring pins in cylinder block -arrows-. t  Note the fitting position of the cylinder head gasket. Identification: You must be able to read the spare part no. from the intake side.   WARNING Pay special attention to avoid damaging the tension rail of the distribution chain during the fitting of the cylinder head. –  If crankshaft has been rotated in the meantime: Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly. –  Fit the cylinder head. In doing so, pay attention to avoid damaging the tension rail of the distribution chain. –  Insert and hand-tighten cylinder head bolts. –  Cylinder head tightening sequence → Fig.   Note Cylinder head bolts do not have to be torqued down again later after repair work.   Note The play of the chain should be between the exhaust camshaft and the crankshaft, to be taken up when the chain tensor is released. –  Fit the distribution chain over the camshaft pinions observing the marks.

–  Remove the upper slide rail for the distribution chain. –  Raise the tension rail (black) of the distribution chain -2- up to its position and mount the guide bolts -1-. –  Remove the clamp -T40011- so that the chain is tensed. –  Extract the counterhold -T20208-.

–  Fit the sub-frame and tighten the bolts -arrows- by hand. –  Tighten the bolts -arrows- of the sub-frame, tightening torques → Chapter. Further installation is carried out in reverse order; note the following: –  Change the engine oil → Booklet101. –  Fill cooling system with fresh coolant → Chapter.   WARNING Do not use charger for boost starting, Otherwise, the vehicle's control units could be damaged.