SEAT Workshop Service and Repair Manuals

Removing and installing cylinder head

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Spring retainer -T10358-

t	Torque wrench (40…200 Nm) -V.A.G 1332-

t	Torque wrench (5…50 Nm) -V.A.G 1331-

t  Adapters -10 - 222 A /28- t  To avoid damaging wing edges, apply adhesive tape -arrow- to bottom areas of both adapters -10 - 222 A /28-.

Removal: –  Unplug connector -1-. –  Remove bolts -arrows-. l  Gas hoses remain connected to gas rail. –  Release the wiring from the fixing of the carrier cover and from the gas hoses. –  Place the fuel rail „Gas rail“ aside and fix without removing the cables and hoses.

–  Remove bolts -arrows- and lift the carrier cover upwards and away. –  Remove the air filter housing → Chapter. –  Remove expanded plastic components or seals in area of wing edges.

–	Remove plenum chamber cover -1- in exterior area → Body - front; Rep. gr.50.

–	Place support bracket -10 - 222 A- with adapter -10 - 222 A /8- behind bonnet stay.

–  Place adapter -10 - 222 A /8- behind bend -2-.   Note Plenum chamber cover is in contact with adapters -10 - 222 A /8-. –  Hook support bracket -10-222 A- into right suspension eye only. –  Remove air duct from air filter with spring-type clip pliers -VAS 5024A- → Chapter.

–  Unscrew securing bolt for gearbox and bolt bracket -T10358- on as shown. –  Attach hooks of support bracket -10 - 222 A- to bracket -T10358- as shown. –  Turn spindles until the hooks are lightly tensioned.

–  Unhook hook -1- from left lifting eye and push spindle onto left side of support bracket -10 - 222 A-. Remove the following components: t  Drain coolant → Chapter. t  Remove intake manifold → Chapter. t  Remove valve timing housing → Chapter. t  Remove timing chain and drive chain for oil pump → Chapter. t  Remove thermostat housing from cylinder head. t  Remove the exhaust manifold with precatalyst. –  Remove camshaft housing → Chapter. –  Remove roller rocker fingers together with support elements and lay aside on clean surface. –  Ensure the roller rocker fingers and the support elements are not confused.

–  Loosen socket head bolts in the sequence given and then remove completely. –  Carefully remove cylinder head. Installation Requirements: l  Pistons must not be at TDC.   Note t  Do not remove the new cylinder head gasket from its packing until immediately before its installation. t  Handle new gasket with extreme care. If damaged, leaks may result. –  Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. –  Carefully clean the sealing surfaces on the cylinder head and cylinder block. Ensure no long grooves or scratches are produced (if using sandpaper. it must be at least 100 grain). –  Carefully remove metal particles, emery residue and cloths. –  Set No. 1 cylinder piston to top dead centre and then turn crankshaft back slightly. –  Fit new cylinder head gasket. Lettering (Part No.) must be readable. –  Fit cylinder head. When doing this, observe centring pins in cylinder block. –  Insert cylinder head bolts and tighten by hand.

–  Tighten cylinder head bolts in tightening sequence as follows: –  Tighten all bolts to 30 Nm. –  Then tighten all bolts 1/4 turn (90°) further using a rigid wrench. –  Then tighten all bolts again 1/4 turn (90°) further –  Install supporting elements in cylinder head and fit respective roller rocker finger onto respective valve stem end or supporting element. –  Fit camshaft housing → Chapter –  Install timing chain and drive chain of oil pump → Chapter. –  Adjust distribution timing → Chapter. –  Fit distribution casing → Chapter. Further assembly is basically the reverse of the dismantling sequence.

–  Install the carrier cover and tighten the screws -arrows- to a tightening torque of 8.5 Nm. –  Mount the cables and gas hoses on to the fixing points of the carrier cover.

–  Install the fuel rail „Gas rail“ and tighten the screws -arrows- to a tightening torque of 4 ± 0.4 Nm. –  Insert the connector -1-.