SEAT Workshop Service and Repair Manuals

Removing and installing cylinder head t  Removing → Anchor t  Installing → Anchor t  Tightening torques → Anchor

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Bracket -T10014- (only for vehicles ► 05.05 with small engine support), see equivalent → Anchor

t	counterhold -T10100-, see equivalent → Anchor

t	Hose clamp -T10051-, see equivalent → Anchor

t	Extractor -T10052A-, see equivalent → Anchor

t	Hose clamp -T10115-, see equivalent → Anchor

t	Hose clamp -T20102-, see equivalent → Anchor

t	Hose clamp -T20167-, see equivalent → Anchor

t	Collecting tray -T20173-, see equivalent → Anchor

t	Base -T20174-, see equivalent → Anchor

t	Bracket -U 30025E- (only for vehicles ► 05.05 with small engine support), see equivalent → Anchor

t  Turning tool -T20197-, see equivalent → Anchor

t  Pressure pump -SAT 1390-, see equivalent → Anchor   Note From 06.05 onwards, an improved engine bracket is fitted which makes it unnecessary to dismantle it and support the motor in the procedure sequence „Timing belt: removing, fitting and tensing“ → Chapter. –  Check which kind of engine support foot the vehicle is equipped with. -1-: Engine mount with small engine support ► 05.05 (removal necessary)

-2-: Engine mount with large engine support 06.05 ► (removal not necessary) Removing   Note Before removing the cylinder head, first the fuel must be extracted from the tandem pump using the Pressure / vacuum pump -SAT 1390- → Chapter.

Engine code letters BJB, BKC, BXE, BXF –  Pull the oil dipstick -1- out of the guide tube. –  Lift the engine cover by the sides -arrows 2- and pull it out forwards -arrow 3-. –  Replace the oil dipstick in the guide tube.

Select engine identification letters BLS –  First remove the outer cover -1- and then the inner cover -2- upwards equally. Continued for all vehicles –  Remove the battery and bracket → Electrical system; Rep. gr.27 . –  Remove the air filter housing → Chapter.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open the cap of the coolant expansion tank.

–  Fit the centre noise insulation -fasteners 1 ... 3-.

–  Fit the right noise insulation -fastening parts 1 ... 3-. –  Drain coolant → Chapter.   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  Wear eye protection.

–  Disconnect the fuel supply hose -2- and return hose -1- from the fuel pipes. –  Remove the coolant hoses -3- . –  Before removing the cylinder head, first the fuel must be extracted from the tandem pump using the Pressure / vacuum pump -SAT 1390- → Chapter.

–  Extract the fuel filter along with the hoses connected to above the support -arrow- and remove to one side. Engine with particle filter –  Remove the front exhaust section with the particle filter → Chapter. Engine without particle filter –  Remove the primary exhaust pipe with catalytic converter → Chapter. Continued for all vehicles –  Remove the bracket for the exhaust gas turbocharger and the oil return line. –  Remove the oil supply line. –  Remove toothed belt → Chapter. –  Remove the notched belt tension roller. –  Separate the hub from the wheel of the camshaft → Chapter.

–  Unscrew the bolts -2- and -4-. –  Unscrew the bolt -3- and remove the Hall sender -G40- from the cylinder head. –  Remove the exhaust gas recirculation connecting pipe. –  Disconnect all other electrical connections as necessary from cylinder head, and lay to one side. –  Remove all other connecting hoses; coolant, vacuum and intake hoses on cylinder head. Only vehicles ► 05.05   Note t  To secure the engine assembly with the support -U-30025E- this must be centred as much as possible with the symmetrical axis of the engine assembly. t  The two rings for the suspension equipment are on the cylinder head. For this, the additional support must be fitted to the engine block in order to support the engine.

–  Fit the support -U-30025E- onto the vehicle and engage the spindle -B - in the cylinder head as shown in the illustration. –  The additional spindle -A- remains free for the moment. –  Pre-tension engine with spindle -B- uniformly and without raising it.

–  Unscrew bolts -1- and -2- and take joint reinforcement off. –  Unscrew bolts -3 ... 6- and take the engine console out.   Note To remove the bolts for the engine support, raise or lower the engine slightly as necessary using the spindles on the engine and gearbox support -U-30025E-.

–  Unscrew the bolts -1 ... 3- from the engine mount. –  Remove the engine supports upwards.

–  Lift the engine and gearbox assembly using the spindle -B-. –  Lower the engine and gearbox assembly once more.   WARNING The rotation of the engine must only take place on the crankshaft in the normal rotation direction of the same (clockwise).

–  Unscrew the threaded pin -1- with the two M8 retention nuts.

–  Tighten the support -T10014- to 20 Nm into the screw hole above the coolant pump. –  Connect the spindle -A- to the support -T10014-. –  Raise the engine with the spindle -A- until the spindle -B- is unloaded. –  Release the spindle -B- from the engine and move to one side. Continued for all vehicles –  Remove cylinder head cover → Chapter

–  Maintain sequence when loosening cylinder head bolts. –  Lift the cylinder head out with the help of a second mechanic. Installing   Note t  Carefully remove any sealant residue from the cylinder head and cylinder block. Ensure that no scoring or scratching is produced. t  Carefully remove any remaining emery and abrasive material. t  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. t  Renew cylinder head bolts. t  When fitting, replace the self-locking nuts and bolts. t  Renew bolts which have a specified tightening angle, as well as seals and gaskets. t  Do not remove the new gasket from its packaging until just before fitting. t  Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks. t  When fitting a new cylinder head with the camshafts fitted, the contact surfaces between the roller rocker arms and the cam contact surfaces must be oiled following the fitting of the cylinder head. t  The plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted. t  Secure all hose connections with the correct hose clips (same as original equipment) → Electronic spare parts catalogue. –  Check if the camshaft and the crankshaft are in TDC: –  Rotate the crankshaft the opposite direction to the direction of rotation until the pistons are almost at the same level under the TDC.

–  Note the cylinder head identification. t  Part No. = -Arrow 1- t  Production code = -Arrow 2- (can be disregarded) t  Holes = -Arrow 3-   Note t  If the gasket or the cylinder head is replaced, fit a new gasket with the same identification. t  If components of the crankshaft mechanism are replaced, the new gasket must be selected by measuring the projection of the pistons at TDC.

–  Place cylinder head gasket in position. l  Note the dowel sleeves -arrows- on the engine block. l  Note the fitting position of the cylinder head; the marking „oben“ (up) or the part number should face the cylinder head. –  Fit cylinder head. –  Insert new cylinder head bolts and tighten hand-tight.

–  Tighten the cylinder head in four stages using the following tightening sequence:

stage:	Tighten
I	–  Tighten using the torque wrench to 35 Nm.
II	–  Tighten using the torque wrench to 60 Nm.
III	–  Turn 90° (1/4 turn) further with the open-ended wrench.
IV	–  Turn 90° (1/4 turn) further with the open-ended wrench.

Note Cylinder head bolts do not have to be torqued down again later after repair work. No. 1 cylinder cams must point upwards.

–  After fitting the cylinder head, turn the camshaft wheel so that the cylinder 1 cams all face uniformly upwards -arrows- . Before fitting the timing belt, turn the crankshaft in the engine rotation direction until it is in the TDC position → Chapter.

–  Insert and tighten bolts -2 … 4- with locking fluid → Electronic parts catalogue. –  Tighten the threaded pin -1- –  Fit the camshaft hub → Chapter. –  Install toothed belt → Chapter.

–  Fit the engine mount on the cylinder block and screw in the attachment bolts -1 … 3- hand tight first. –  Then tighten the bolts -1 ... 3- to 40 Nm + 1/2 turn (180°). –  Install poly V-belt → Chapter. –  Install cylinder head cover → Chapter. –  Fit the oil feed tube. Engine codes BJB, BKC, BXE, BXF and BLS without particulate filter –  Remove the front section with catalytic converter → Chapter. Engine code BLS with particulate filter –  Install the front section with particulate filter → Chapter. Continued for all vehicles –  Install the exhaust system and align free of stress → Chapter. –  Fit the supercharger air system hoses and observe the assembly instructions → Chapter. –  Connect battery. Precautions → Electrical system; Rep. gr.27. –  Check oil level → Chapter.   Note Carry out an engine oil change if this is dirty → Booklet2. –  Fill up coolant → Chapter. –  Carry out a test drive and interrogate the event memory → Vehicle diagnostic tester. Tightening torques Engine code letters BJB, BKC, BXE, BXF

Component		Nm
Notched belt rear protection to cylinder head		10 → Remark
Hall sender to the cylinder head		10 → Remark
Pin to cylinder head		15
Hub to the camshaft		100
Oil pressure switch to oil filter bracket		20
Oil supply pipe to the turbocharger		22
Oil supply pipe to oil filter bracket		22
Oil return pipe to the engine block		30
Bracket	to turbocharger	20
Turbocharger	To engine block	40
Front air hose	To engine block	15
	to bracket	8

1)  Fit with locking fluid; locking fluid → Electronic parts catalogue Select engine identification letters BLS

Component			Nm
Hall sender -G40- to the cylinder head			10 → Remark
Notched belt rear protection to cylinder head		M6	10 → Remark
		M8	25 → Remark
Hub to the camshaft			100
Centre section of notched belt guard to cylinder block			10 → Remark
Bottom section of notched belt guard to cylinder block			10 → Remark
Exhaust gas recirculation radiator to intake manifold			22
Turbocharger support to	Turbocharger		25
	cylinder block		60
Oil return pipe to the turbocharger			15
Exhaust gas recirculation joint hose	exhaust gas recirculation radiator		22
	Exhaust manifold		25
Front crosspiece of the vehicle to the bodywork			22
Heat shield to cylinder block			35
Ribbed belt tensioner to ancillaries bracket			23
Guide tube for the dipstick to	Oil filter bracket		10
	Attachment ring		10
Support for the oil supply pipe			10
Oil supply pipe to oil filter bracket			22
Oil pressure switch to oil filter bracket			20
Right air hose to bracket			8

2)  Fit with locking fluid; locking fluid → ETKA (electronic parts catalogue)