SEAT Workshop Service and Repair Manuals

Cylinder head: Removing and installing (engine codes BZB - CCZB - CDAA) 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	attachment tool -2024A- → Anchor

t	counterhold -T10014-, see equivalent → Anchor

t	Assembly tool -T10352-, assembly tool -T10352/1-, see equivalency → Anchor

t	Spanner -T10355-, see equivalent → Anchor

t	Counterhold -T40011-, see equivalent → Anchor

t	Extractor -T40039-, see equivalent → Anchor

Special tools and workshop equipment required

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	Tray -VAS 6208-

t	Spanner -T10070-

Removing –  Carefully remove engine cover → Chapter.   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. –  High pressure system pressure reduction → Chapter.

–  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-.

–  Release the hose clamp -2-. –  Remove bolt -4-. –  Unplug the connector -arrow- 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-.

Four wheel drive vehicles –  Unbolt heat shield for right drive shaft -arrows-. –  Uncouple the right-hand side drive shaft from the gearbox flange and remove it towards the vehicle rear.

Vehicles with front-wheel drive –  Unbolt heat shield for right drive shaft -arrows-.

All other vehicles continued –  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. Vehicles with front-wheel drive –  Unscrew the bolts -1- for the oil return line. Four wheel drive vehicles –  Unscrew bolts for oil return line on crankcase. All other vehicles continued –  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.

–  Detach the connector for valve 1 of the variable valve timing -N205--1- –  Unplug electrical connectors at ignition coils and move wiring harness clear.

–  Remove ignition coils using puller -T40039-.

–  Remove the air duct hose -2- and move it 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.

–  Disconnect crankcase breather hoses -1 and 2-. –  Remove bolts -arrows- and detach crankcase breather.   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-.

–  Unscrew the turbocharger oil supply conduit -1-.

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

–  Unplug connectors -1 to 4-. –  Free the attachment cable -5-. –  Detach the vacuum duct-6- to the active carbon filter.

–  Separate the connector -1- and remove it from the bracket. –  Unplug connectors -2 to 4-. –  Remove the vacuum duct -5-.

–  Unscrew the bolts -arrows- and separate the coolant hose from the intake manifold.

–  Unscrew the fastening nut -1- and the bolt -2- and remove the manifold intake support. –  Remove the oil filter with the extractor -3417-.

–  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-.

–  Unscrew bolts -arrows- and remove camshaft control valve 1 -N205-.

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

–  Remove the control valve with the wrench -T10352- or with the wrench -T10352/1- in the direction of the -arrow-. t  With those engines with identification letters BZB , using the Assembly tool -T10352-. t  With those engines with identification letters CCZB- CDAA, using the Assembly tool -T10352/1-

–  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. l  The markings -1- on the camshafts must face upwards.

–  Use a waterproof pen to mark drive chain / chain sprockets -arrows-. Also mark the position of the drive chain / guide rail -arrows B-. The marking is required for reinstallation.

–  Remove sealing plug -arrow-. To enable the chain tensioner to be slackened, the locking element in the chain tensioner must be raised. For this purpose, grind the tip of the locking pin -T40011- in such a way that it becomes sharp. A screwdriver with a blade width of approx. 1.5 mm can also be used.   Caution Risk of damaging the chain tensioner! Proceed with great care.

–  Lift the locking element in chain tensioner by inserting a screwdriver in the hole of the chain tensioner in direction of arrow -1-. –  To tension the chain tensioner, turn the crankshaft counter to direction of engine rotation in direction of arrow -2- and secure with the locking pin -T40011-.   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.   Caution Risk of damaging valves, piston crowns and lower timing chain cover. t  Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinder head. t  Sheet metal elements which prevent the chain from falling down are located on the bottom cover for the timing chain. If the crankshaft is turned with the chain loose, these sheet metal elements can be deformed.

–  Extract the caps -arrows- turning them 90° anti-clockwise, in the -direction of the arrow-. –  Ball head -1 ... 2-. –  Detach oil filler cap.

–  Remove bolts -arrows-. –  Unscrew the cylinder head bolts in the sequence -1 ... 5- with the special wrench, long reach -T10070- except for 2 items.   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. –  Unscrew the final two cylinder head bolts.   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  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  If installing an exchange cylinder head, the camshafts must be set to »TDC« and the mark on the old chain sprockets must be transferred to the new chain sprockets (note factory colour marking on chain sprockets). t  If an exchange cylinder head is installed, all the contact surfaces between the supporting elements, roller rocker fingers and the running surfaces of the camshaft must be oiled before the cylinder head cover is installed. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and coolant.

–  Hang the lifting tackle -2024A- onto the workshop hoist -VAS 6100- and above the motor block.   Caution t  Carefully lower cylinder head. t  Do not damage tensioning and sliding rails under any circumstances. –  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.   Caution Make sure that components are not damaged by the timing chain when rotating the crankshaft. –  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 t  Turn inlet camshaft using spanner to fit cylinder head bolts. t  Cylinder head bolts do not have to be torqued down again later after repair work.   Caution Make sure that components are not damaged by the timing chain when rotating the crankshaft.

–  Rotate the vibration damper with the retention tool -T10355- to the »TDC position«-arrow-. l  The notch on the vibration damper should face the mark -arrow- on the lower cover of the distribution chains.

–  Fit timing chain onto the inlet camshaft. The markings must align. –  Turn inlet camshaft with wrench in -direction of arrow- until the timing chain is lying »tightly« against the guide rail. »Hold« the inlet camshaft in this position.

–  Fit timing chain onto exhaust camshaft: The markings on the drive chain / chain sprockets -arrows A- and drive chain / guide rail -arrows B- must be in line with each other.

–  Remove the upper slide rail for the distribution chain. –  Move tensioning rail -2- upwards and tighten bolt -1-.   Note

If the markings on the drive chain / guide rail -arrows B- no longer align even though the engine is at »TDC«, the drive chain may have jumped at the chain sprocket of the crankshaft. Check valve timing → Chapter If the timing is not correct, the camshaft timing chain has to be taken off and fitted »again« → Chapter. Further installation is carried out in reverse order; note the following: –  Change the engine oil → Booklet3. –  Fill cooling system with fresh coolant → Chapter.   WARNING Do not use charger for boost starting, Otherwise, the vehicle's control units could be damaged.