SEAT Workshop Service and Repair Manuals

Cylinder head: removal and installation (2.0 litre engine) (without free space for the screwing tool)   Note The camshaft without free space for the screwing tool do not have any recesses → Fig.. t  Removing → Anchor t  Installing → Anchor Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter Special tools and workshop equipment required

t  Engine sealing plug set -VAS 6122-, see equivalent → Anchor Removing   Caution Risk of severe damage to the electronic components when disconnecting the battery. Observe the correct procedure for disconnecting the battery → Rep. gr.27.   Note t  Fit cable ties in the original positions when installing. t  All open passages in the intake and exhaust systems must be sealed with suitable plugs, for example from the engine sealing plug set -VAS 6122-. –  Remove camshafts → Chapter.   Caution Avoid damage to valves and piston crowns. The crankshaft must not be rotated if the camshafts have been removed. –  Remove front exhaust pipe/front silencer → Chapter.

–  With ignition switched off, disconnect earth wire -arrow- at battery.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open cap on coolant expansion tank.

–  Loosen the fasteners -2-, -3- and -5- and remove the front noise insulation. –  Drain coolant → Chapter.

–  Unscrew earth connection -1-. –  Disconnect vacuum hose going to brake servo at bulkhead -2-. –  Disconnect ACF hose -3-. –  Disconnect coolant hoses on rear of cylinder head.

–  Disconnect fuel lines -1 and 2-.   Caution Protect fuel system against contamination. Rules for cleanliness when working on the injection system → Chapter.

–  Detach the coolant hoses -1-, -2- and -3- and unscrew the coolant expansion tank -arrow-. –  Separate the connector of the switch for coolant shortage indicator -F66- below on the coolant compensation tank.

–  Unplug the following electrical connectors: 2 -  From knock sensor 1 -G61- (unplug and move clear) 3 -  From intake manifold flap valve -N316-, fuel pressure sender -G247- and Hall sender -G40- 4 -  From injectors 5 -  From throttle valve module -J338- 6 -  From intake air temperature sender -G42-

–  Remove the connector -1-. –  Remove electrical cable -2-

–  Unbolt bracket for coolant pipe -arrow-.   Note The installation position is shown in the following illustrations with the engine removed.

–  Remove intake manifold support (remove securing nut -1- and bolt -2-).

–  Disconnect coolant hose -arrow-.

–  Unscrew bolts -1 and 2- and move oil supply pipe clear to one side. –  Unscrew bolt -3- and move coolant pipe clear to one side.

–  Open hose clip -arrow-, detach air hose and swivel to side.

–  Unplug electrical connectors -1 and 4- from oil pressure switch -F22- and oil pressure switch for reduced oil pressure -F378-.

–  Unplug electrical connectors -1 and 2- and move wiring clear.

–  Remove bolts -arrows- and detach support for turbocharger.

–  Remove bolts -arrows- at oil return pipe.

–  Unscrew nuts -arrows- and push catalytic converter to rear. –  Remove the spark plugs when using the spark plug spanner -3122 B-.

–  Remove bolts -arrows-. –  Unscrew the bolts from the cylinder head in the sequence -1 … 10-.   Note 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. –  Remove the cylinder head. –  Place cylinder head onto soft surface (foam plastic). Installing l  Tightening torques → Chapter   Caution Avoid damage to sealing surfaces. t  Carefully remove sealant residue from cylinder head and cylinder block. t  Ensure that no long scores or scratches are made on the surfaces. 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 cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket. Avoid damage to open valves. 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. Avoid damage to valves and piston crowns after working on valve gear. 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  Consider the different sealant types that have to be used for the sealing surface and the bolt of the cylinder head. t  When installing an exchange cylinder head, the contact surfaces between the hydraulic compensation elements, roller rocker fingers and cams must be oiled before installing the camshaft. t  Hose connections and air pipes and hoses must be free from oil and grease before fitting. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the charge air hoses can be connected securely, you must spray the screws on used screw-type clips with rust remover prior to installation. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and coolant.

–  Place cylinder head gasket in position. t  Note position of centring pins in cylinder block -arrows-. t  Observe correct installation position of the cylinder head gasket. Identification: The part number must be legible from the inlet side.   WARNING Make sure that components are not damaged by the timing chain when rotating the crankshaft. –  If crankshaft has been rotated in the meantime: Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly. –  Fit cylinder head. –  Insert and hand-tighten cylinder head bolts. –  Tightening sequence of the cylinder head → Fig.   Note Cylinder head bolts do not have to be torqued down again later after repair work.

–  Turn vibration damper to „TDC“ position -arrow- using counterhold tool -T10355-. l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom). Continue the assembly in the reverse order to removal, considering the following in the process: –  Install camshafts → Chapter. –  Install timing chain cover (top) → Chapter. –  Change engine oil → Booklet301. –  Fill cooling system with fresh coolant → Chapter. –  Remove catalytic converter → Chapter. –  Install front exhaust pipe/front silencer → Chapter.   WARNING Do not use charger for boost starting, Otherwise, the vehicle's control units could be damaged.