SEAT Workshop Service and Repair Manuals

Install cylinder head cover   Caution The M6 x 70 studs must be screwed in the cylinder head before fitting the cylinder head cover. The head bolts are used to guide the cylinder head cover and prevent that the roller rocker fingers loosen from the support elements. –  Remove the sealant residues from the cylinder head cover and the cylinder head using a rotating brush, e.g. a hand drill machine with plastic brush (wear protective goggles). –  Clean sealing surfaces carefully. They must be free of oil and grease. –  Also prevent dirt and sealant remnants from entering cylinder head. Premise l  Pistons must not be at TDC.

–  Bolt 2 studs (M6 x 70) on the cylinder head before fitting the cylinder head cover.-1-   Caution The cylinder head cover is sealed with 2 different sealants!   Note The sealant must not be applied too thickly otherwise excess sealant could enter the oil channels and cause damage to the engine. –  Clean sealing surfaces carefully. They must be free of oil and grease. –  Apply the sealant D 189 500 A1 -1- onto the sealing surface.

The line of sealant should not be thicker than 2 ... 3 mm and must go along the inner side of the tapped holes. –  Apply a thin and even coating of the sealant D 154 103 A1 onto the sealing surface -2-. –  Check whether all roller rocker fingers contact the supporting elements. –  Position the cylinder head cover carefully on the studs and dowel pins in the cylinder head.

–  Remove the new securing bolts of the cylinder head cover in the following order -A - to -J-. Tightening torque: 8 Nm and then turn 90° further   Caution The sealant for the cylinder head cover must be removed in the areas of the -arrows-. Both sealants for the cylinder head cover and for the valve timing housing should not be mixed to prevent leaks.

–  Remove the surplus sealant in the area of the -arrow-. –  Turn the crankshaft to the end point in the direction of the operation of the engine.

–  Lift the timing chains with the assembly tool -T10118-.   Caution The oil sump only has to be removed with vehicles ► 12.2009. On these vehicles, the distribution chain can be separated from the crankshaft during installation.

–  Check the correct position of the timing chains -1- on the crankshaft gear from below.

For all vehicles –  Fit the timing chains -1- on the pinion -2-. The timing chain must be in the section of the guide rail -3- and be slightly taut. –  Tighten the new securing bolt by hand. The distribution chain must run across the centre of the tensioning rail.

–  Tighten the chain tensioner to 60 Nm.

–  Tighten the camshaft sprocket with a new securing bolt -arrow 1- to 50 Nm.   Note The securing bolt is rotated another 1/4 90° after checking the valve timing at the end of the process. –  Immobilise the camshaft wheel using the counterhold tool -T10172-. –  Remove the camshaft clamp -T10414- from the camshaft. –  Unscrew the locking bolt -T10340- from the cylinder block. –  Turn the crankshaft in the direction of engine by 2 rotations. –  Tighten the securing screw -T10340- until the end point in the crankshaft sump. –  Turn the crankshaft to the end point in the direction of the operation of the engine. If the camshaft fastener -T10414- can be fitted to the camshaft, the control timings are correct. If the control timings are not correct: –  Repeat the valve timing adjustment once more .

–  Rotate the securing bolt another -1-1/4 turn (90°). –  Immobilise the camshaft wheel using the counterhold tool -T10172-. –  Remove the camshaft fastener -T10414- and the locking bolt -T10340-. –  Upper distribution housing: Installing → Chapter. –  Install the turbocharger → Chapter. –  Install sump → Chapter. –  Pulley for the crankshaft: Installing → Chapter –  Install high-pressure pump → Chapter. –  Connect the fuel lines → Chapter. –  Further assembly is basically the reverse of the dismantling sequence.