SEAT Workshop Service and Repair Manuals

Removing and installing the cylinder head, 1.8 litre engine 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	Assembly tool -T10352- and assembly tool -T10352/1-, see equivalent → Anchor

t	Hose clamp -T10355-, see equivalent → Anchor

t	Spanner -T20079A-, see equivalent → Anchor

t	counterhold -T20208-, see equivalent → Anchor

t	Hose clamp -T40011-, see equivalent → Anchor

t	Extractor -T40039-, see equivalent → Anchor

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

t  Torque wrench -VAG 1331-, see equivalent → Anchor. t  Torque wrench -VAG 1332-, 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  The cable ties must be installed in their same place again. 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-.

–  Disconnect battery earth cable -arrow- with ignition switched off.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open the Sealing plug of the coolant expansion tank.

–  Loosen the fasteners -2-, -3- and -5- and remove the front noise insulation.   WARNING Hot coolant and vapours can cause burns! t  When the engine is hot the cooling system is under pressure. t  To reduce the system charge pressure, cover the expansion tank plug with a rag and open carefully. –  Drain coolant → Chapter.

–  Pull off engine cover panel -arrows-. –  Remove bolts from connector rail for ignition coils.

–  Release connectors -arrows- and unplug all connectors from the ignition coils at the same time.

–  Unscrew the earth cable -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 Observe rules for cleanliness when working on the fuel supply system. –  Move lock carrier to service position → Rep. gr.50.

–  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 electrical connector from charge air pressure sender -G31--1-. –  Remove charge air hose (left-side) -2-.

–  Unscrew both bolts-arrows- for the air pipes -1- on the lock carrier plate.

–  Loosen the bracket -1-, disconnect the air hose and swivel to the side. –  Disconnect the connector -2- from the air mass meter -G70-. –  Unclip cable harness from air cleaner housing and lay down to side. –  Loosen expansion clip -3- and separate air cleaner housing. –  Pull upward to loosen lower mounts and to remove air cleaner housing.

–  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 For improved illustration purposes, the installation position is shown in the following 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.   Note Never bend the damping element on the front section of the exhaust pipe with particulate filter more than 10°, otherwise it can be damaged.

–  Loosen clamping sleeve -arrows- and push to rear.

–  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).

–  Remove the control valve using the assembly tool -T10352- or assembly tool -T10352/1- in the -direction of the arrow- depending on the version.   Caution The control valve has a left hand side thread.

–  Unscrew the bolts -arrows- and remove the subframe.

–  Turn the vibration damper to „TDC“ position -arrow- using counterhold tool -T10355-. l  The notch on the vibration damper should face the mark -arrow- on the lower cover of the distribution chains.

–  Use a waterproof pen to mark drive chain/chain sprockets -arrows-.

–  Remove sealing plug -arrow-.   Note t  The box -1- is shown in a removed condition in the following figures to provide a better view.

t  Lift the locking element -2- with a scriber or suitable screwdriver -3- in -the direction of the arrow-.

–  Insert scriber or suitable screwdriver in hole of chain tensioner in direction of -arrow 1- and lift locking element for chain tensioner. –  Turn crankshaft in opposite direction to normal rotation -arrow 2- and lock in place using 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. –  Remove camshaft timing chain from camshaft sprockets.   Caution Risk of damage to valves and piston heads. Once the camshaft chain has been extracted from the cylinder head, the crankshaft must not turn.

–  Remove ignition coils using puller -T40039-.

–  Remove crankcase breather hose -1-. –  Remove bolts -arrows-, detach crankcase breather system and disconnect from crankcase breather hose -2- in direction of -arrow-.

–  Turn sealing plugs -arrows- 90° anti-clockwise -arrow- and remove. –  Ball head -1 ... 2-. –  Detach filler cap.

–  Unscrew bolts -arrows-. –  Remove cylinder head bolts in the 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. –  Remove the cylinder head. –  Place cylinder head onto soft surface (foam plastic). Installing l  Tightening torques → Chapter   Caution Risk of damaging the contact 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. Risk of damage to the engine! 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. Risk of damaging the 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  Replace the bolts tightened using goniometrics. t  Always replace seals, gaskets and self-locking nuts t  Take into account the different gasket pastes that should be used for the sealing surfaces and for the cylinder head bolts. t  Secure hose unions with hose clamps the same as those of the series → Electronic parts catalogue. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and coolant.

–  Positioning the cylinder head gasket. t  Observe the centring pins on the 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.   Note Turn inlet camshaft using spanner to fit cylinder head bolts. –  Tightening sequence for cylinder head → Fig.:   Note Cylinder head bolts do not have to be torque down again later after repair work.

–  Turn the 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).   Note The timing chain links with markings must be positioned at the markings on the chain sprockets.

–  Insert the spanner to turn inlet camshaft in direction of -arrow- and fit camshaft timing chain. The markings on the camshaft timing chain and the cylinder head -arrows- must align with the sprockets -1-.

–  Attach bearing saddle and screw in bolts -arrows- hand-tight. –  Remove locking pin -T40011-. –  Tighten bolts -arrows- for bearing saddle → Chapter. –  Install timing valve → Item. The remaining installation steps are carried out in the reverse sequence. Note the following points: –  Change engine oil → Booklet301. –  Install timing chain cover (top) → Chapter. –  Replace the coolant → Chapter. –  Install catalytic converter → Chapter.   WARNING Do not use charger for boost starting, Otherwise, the vehicle's control units could be damaged.