SEAT Workshop Service and Repair Manuals

Cylinder head: Removing - vehicles with large engine support   Note

For the dismounting of the cylinder head in vehicles with large engine support foot -2- it is not necessary to dismount the engine support foot. Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Hose clamp -T10051-, see equivalent → Anchor

t	Extractor -T10052A-, see equivalent → Anchor

t	Hose clamp -T20102-, see equivalent → Anchor

t	counterhold -T20127-, see equivalent → Anchor

t	Collecting tray -T20173-, see equivalent → Anchor

t	Workshop crane

t	Hose clamp -T10050-, see equivalent → Anchor

t	Hose clamp -T10100-, see equivalent → Anchor

t	Bent screwdriver -T10264-, see equivalent → Anchor

t	Retention tool -T10265-, see equivalent → Anchor

t  Hose clamp -T20167-, see equivalent → Anchor Operation process   Note t  To carry out this work it will be necessary to disconnect battery earth strap. Therefore check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. 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 Observe safety precautions when disconnecting the battery → Electrical system; Rep. Gr.27. –  Open the cap of the coolant expansion tank.

–  Place the drip tray -T20173- under the engine. –  Separate the coolant hose from the radiator; to do this, extract the lower retainer -arrow-.

–  Additionally take coolant hose on upper part of oil cooler off -arrow- and drain off remaining coolant.

–  Remove the right soundproofing -Anchorage parts 1 ... 3-.

–  Unscrew the nuts -2- and the bolts -3- and remove the connecting pipe for exhaust gas recirculation.   Note Item -1- can be disregarded. Continue only for vehicles with front wheel drive

–  Unbolt the heat protection plate of the right half-shaft -arrows-. Continue only for vehicles with four wheel drive

–  Unscrew the insulating panel for the right half shaft from its mounting at the angular gears -arrows-. –  Remove the right-hand drive shaft → Rep. Gr.40.

Continued for all vehicles –  Unscrew nuts -1-, the bolt -2- and the hollow bolt -3- and remove the turbocharger support.

–  Unscrew nuts -1- and -3-, as well as the screw -2- and remove the particle filter support.

–  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards.

–  Remove the air conduit cover by releasing the side tabs -arrows-.

–  Unclip the air conduit in the lower part by releasing the tabs -arrows-. –  Remove the lower section of the air duct together with the air hose.

–  Separate the electrical connector -1- from the air mass gauge -G70-. –  Uncouple the flexible air hose -3- and the flexible air conduit -2-. –  Unscrew the bolt -4- and remove the air filter housing.

–  Detach the flexible tube -2- from the crankcase breather. –  Remove the flexible air hose -4- and the pressure hoses -3- together with the air conduit flexible hose. –  Loosen the clamp -1-.

–  Turn back the flexible air conduction tube and detach it from the exhaust gas turbo compressor.   WARNING t  For those vehicles fitted with an injector pump, the temperature of the fuel and the fuel lines may reach up to 100 ºC in extreme cases. Before opening the duct connections, allow the fuel to cool otherwise there is a risk of severe burns. t  Wear protection gloves. t  Use protective goggles. –  In the tandem pump dismount the supply flexible tube -2- (white mark) and of the fuel return -1- (blue mark).

–  Separate the coolant hoses -1 ... 4-.

–  Disconnect electrical connection -arrow- from the fuel temperature sender -G81-. –  Set aside the electrical wiring.

–  Free the depression hose in the mounting clip -arrow-. –  Unscrew the bolts -1, 4 and 5-. –  Uncouple the depression flexible hose -2- to the pressure capsule for the air flow control.   Note Ignore positions -3- and -6-.

–  Separate from the support the throttle valve in the intake manifold -N316--arrow-. –  Dismount the throttle motor in the intake manifold -V157- → Chapter. –  Dismount the exhaust gas recirculation valve -N18- with the exhaust gas recirculation potentiometer -G212- → Chapter.

–  Remove the switching valve for the radiator for the exhaust gas recirculation -N345-- 2- from its bracket. –  Detach the electrical connectors -1- and -3- and leave the wires free. –  Detach the pressure hoses -4, 5, 6-. –  Unscrew bolts -arrows-. –  Free the electrical wires and the depression hoses.

–  Uncouple the electrical connector -3- for the exhaust gas temperature sender 1 -G235- and free the electrical wiring.   Note Disregard - Items 1, 2, 4, 5-.

–  Remove the oil supply hose -3- of the turbocharger. –  Unscrew bolt -1-. –  Pull the fastening tabs out a little -arrows- and remove the air hose. –  Remove nut -2-. –  Turn the depression hose a little to the left.

–  Move electric lines for exhaust gas temperature sender 1 -G235--item 1- clear.   Note Ignore the -arrows-.

–  Release the clamp -1- for the particulate filter and remove it. –  Push the particle filter lightly backwards.   Note Disregarding of -item 2 … 5-.

–  Disconnect electrical connection -arrow- from the coolant temperature sender -G62-.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Disconnect the centre connector for the injector pump units and the glow plugs. –  Set aside the wiring harness.

–  Detach the depression hose -1- of the tandem pump. –  Detach the pressure hose -4- in the retention valve. –  Detach the depression hose -2-. –  Remove the rubber bushing -3- of the engine suspension lug.

–  Unscrew the coolant hose -arrows-.   Note

Before removing the ribbed belt, mark its running direction with chalk or with a felt tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause it to rupture. –  Slacken ribbed belt, turn tensioning element in -direction of arrow-.

–  Lock tensioner with retention tool -T20167-. –  Remove the ribbed belt.

–  Remove tensioning device for ribbed belt -arrows-.

–  Remove the upper protection for the notched belt; to do this, release the attachment clips -arrow-.

–  Remove the vibration damper hood. –  Unscrew the vibration damper.   Note To loosen and to tighten the vibration damper, hold it on the centre bolt using a ring spanner.

–  Unscrew the lower and centre notched belt guard -arrows-.   WARNING The rotation of the engine must only take place on the crankshaft in the normal rotation direction of the same (clockwise). –  Rotate the crankshaft to the TDC of cylinder 1.   Note

t  Rotate the crankshaft until the marks on the timing belt wheel of the crankshaft and the gear segment of the camshaft wheel face upwards. The mark on the timing belt protection should coincide with the mark on the generator wheel of the camshaft -arrows-. t  Immobilise the hubs using the retention tools -T20102-. t  Immobilise the crankshaft timing belt wheel with the counterhold -T10050- or the counterhold -T10100-. To do so, insert the counterhold in the gear teeth at the front of the timing belt wheel.

Vehicles with round wheel for the crankshaft timing belt –  Immobilise the crankshaft notched belt wheel using the retention tool -T10050-.

Vehicles with an oval wheel for the crankshaft timing belt –  Immobilise the crankshaft timing belt wheel using the crankshaft stop -T10100-.   Note

The marks on the timing belt wheel -2- and on the crankshaft stop -T10050- or crankshaft stop -T10100--1- should face each other. For this, the stub of the counterhold -T10050- or counterhold -T10100- should match the opening in the sealing flange.

–  Mark the notched belt direction of rotation with chalk or felt pen. –  Loosen the mounting screws -arrows- of the wheels of the cam shafts until the camshaft wheel may turn on the shafts..

–  Loosen the securing nut -1- of the tensioning roller. –  Turn the tension roller cam with the Bent screwdriver -T10264- counter clockwise -arrow- until the tension roller can be immobilised with the Retention tool -T10265-.

–  Next turn the off-centre adjustment in the direction of the -arrow- as far as possible and hand tighten the fastening nut -1-. –  Remove the timing belt, first from the coolant pump and then from the rest of the timing belt wheels.

–  Extract the retention tool -T20102-. –  Unscrew the bolts -arrows- of the camshaft wheels. –  Remove the camshaft wheels.

–  Loosen the mounting screw -1- of the intake camshaft bin with the help of the retaining tool -T10051-.

–  Loosen the mounting screw -1- of the intake camshaft bin with the help of the retaining tool -T10051-. –  Remove securing bolts of the hubs about 2 rotations.

–  Fit the extractor -T10052- to the supply cam hub and tighten the bolts -arrows- on the hub. –  Extract the hub, hold the nut (e/c 30) on the extractor and tighten the bolt -1-.

–  Fit the extractor -T10052- to the supply cam hub and tighten the bolts -arrows- on the hub. –  Extract the hub, hold the nut (e/c 30) on the extractor and tighten the bolt -1-. –  Remove the timing belt tension roller.

–  Unscrew bolts -2 to 4-. –  Unscrew bolts -5- and remove the Hall sender -G40- from the cylinder head. –  Unscrew nut -1- of the tension roller.

–  Unscrew the bolts for the cylinder head cover in the sequence -11 … 1-. –  Remove cylinder head cover.

–  Unscrew bolts -1-, -3- and -5-. –  Loosen the bolts -2- and -4- alternately in several steps and unscrew them.   Note Do not remove the screws of the rocker arm shaft so that they stay fixed in the shaft. If necessary, mark the position with the rocker arm. –  Remove the rocker arm shaft. –  Unscrew the bolts -6 ... 10-.

–  Loosen the cylinder head screws respecting the order.

–  Place the retaining tool -T20127- in the cylinder head joint supports and in the shop crane, as shown in the figure.   DANGER! Ensure that the hooks are closed with the security rings. –  Raise a little the cylinder head with the shop crane. –  Turn the cylinder head to the left, removing it from the toothed belt rear protector and at the same time remove the tension roller. –  Place the cylinder head over a soft surface with the combustion chamber side facing up.