SEAT Workshop Service and Repair Manuals

Cylinder head: Removing and installing t  Removing → Anchor t  Installing → Anchor t  Tightening torques → Anchor

Special tools and workshop equipment required

t	Torque wrench -SAT 8010-

t	attachment tool -T10014-

t	Counterhold tool -T10050-

t	Counterhold tool -T10051-

t	Extractor -T10052-

t	Counterhold tool -T10115-

t	Counterhold tool -T20102-

t	Counterhold tool -T20167-

t	Tray -T20173-

t	attachment tool -T20174-

t	Retainer -U-30025E-

t  Rotation tool -T20197-

t  Hand pump -SAT 1390- Removing   Note t  To carry out this work it will be necessary to disconnect battery earth strap. For this purpose, first 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 When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  All the various lines (e.g. fuel, hydraulic system, active carbon filter system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring must be installed in their original positions. t  Ensure that there is sufficient clearance to all moving or hot components.   WARNING Note the precautionary instructions for disconnecting the battery. → Electrical system; Rep. gr.27 –  In vehicles equipped with a coded radio or coded radio and navigation system (RNS), the code should be noted, obtaining the code where necessary.

–  Remove the central soundproofing → Bodywork, exterior installation work; Rep. gr.50. –  Remove front right hand side wheel housing liner → Bodywork, exterior fitting work; Rep. gr.63. –  Drain coolant → Chapter.   WARNING t  The fuel system is pressurised. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. 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.

–  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards. –  Remove air filter → Chapter.

–  Remove the fuel supply hose -1- (white mark) and return hose -2- (blue marking) from the fuel filter. –  Connect the manual pump -SAT 1390- to the fuel return hose -2- using thetank -SAT 1390/1-. –  Operate the pump until no more fuel comes out of the flexible return tube. Ensure that fuel does not enter into the manual pump.

–  Disconnect the fuel lines from the pipes on the cylinder head -arrows-.

–  Extract the vacuum hose to the brake servo from the tandem pump -arrow-.

Unplug the following electrical wiring connections: 2 -  Glow-plug plug 3 -  Injected pump plug 4 -  Crankshaft impulse sensor plug 5 -  Camshaft impulse sensor plug 6 -  Oil pressure sensor plug 7 -  Fuel temperature sensor plug –  Move the cable harness to one side.

–  Unplug the electrical connector -arrow- from the coolant temperature sender -G62-.

–  Separate the upper coolant hose from the radiator at the engine connection hose as well as the rest of the hoses -arrows- using the retaining tool -T20174-. Engines with codes BNM, BNV and BMS –  Separate the coolant hoses from the exhaust gas radiator and move them to one side.

Engines coded with AMF, BNM and BNV –  Remove the supercharger air tube -1- along with the connection tube -2- by separating the spring clips or securing clips -arrows- . Engines coded BMS

–  Remove supercharging tube -2- with connecting hose -3-, releasing the brackets -arrows-. –  Disconnect connection -1- from the intake manifold air pressure sender -G71-.

–  Detach electrical connector -1- of the engine intake manifold flap -V157-.

BNM and BNV engines –  Separate the electrical connection -arrow- from the intake manifold flap motor -V157- .

Engines coded with AMF, BNM and BNV –  Separate the breather hose for the crankshaft sump -2- from the supercharger air pipe -5-. –  Unscrew bolts -3- and -4- from the supercharger air duct → Item .

–  Remove the supercharger air tube -1- from the turbocharger using the counterhold -T20174- . –  Disconnect the suction and vacuum hose connections. Engine codes AMF, BNM, BNV –  Unscrew the nuts -2- from the front exhaust tube and remove it → Chapter . Engines coded BMS –  Unscrew the front exhaust section with the particulate filter but do not remove it → Chapter.

Continued for all vehicles –  Unscrew the oil delivery tube coupling nut -8- and the securing bolt -6- from its housing. –  Unscrew the oil return tube coupling nut -5- from the coupling connection.

–  Unscrew the oil delivery tube coupling nut -3- and the securing bolt -4- from its housing. –  Extract the oil feed tube .   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. –  Remove toothed belt → Chapter. –  Separate the hub from the wheel of the camshaft → Chapter. –  Remove the timing belt tension roller → Item. –  Remove the Hall sender -G40- . –  Remove the coolant pump → Chapter. –  Remove rear part of timing belt guard → Item

–  Tighten, as shown, the support tool -T10014- into the front screw hole of the engine support, removed in the area of the engine block coolant pump. –  Lift engine slightly using spindle -A- until spindle -B- is relieved. –  Disconnect the spindle -B- from the engine ring -1- and move it to one side. –  Removing and fitting the cylinder head cover → Chapter.

–  Maintain sequence when loosening cylinder head bolts. –  Lift and remove the cylinder head with the help of a second operator. Installing   Note t  Carefully remove any remains of sealant from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces. t  If repairing, carefully remove any remains of gasket material from the cylinder head and cylinder block. Make sure that no long scores or scratches are made on the surfaces. If sandpaper is used, the grain should not be less than 100. t  Carefully remove emery and abrasive remains. t  No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. t  Insert cylinder head bolts and tighten by hand. 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 cylinder head gasket from its packing until immediately before its installation. t  Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks. 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) → Parts catalogue.

–  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. –  Manually fit the cylinder head attachment bolts.

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

stage:	Tighten
I	–  Tighten using the torque wrench to 40 Nm.
II	–  Tighten using the torque wrench to 60 Nm.
III	–  Turn further with rigid spanner 90° (1/4 turn).
IV	–  Turn further with rigid spanner 90° (1/4 turn).

Note Cylinder head bolts do not have to be torqued down again later after repair work. –  Check if the camshaft and the crankshaft are in TDC:

No. 1 cylinder cams must point upwards -arrows-.

The crankshaft notched belt wheel must be immobilised using the crankshaft stop -T10050-.   Note The marks on the notched belt wheel -2- and on the crankshaft stop -T10050--1-should face each other. For this, the crankshaft stop -T10050- journal should match the opening in the sealing flange.

–  Fit and tighten the bolts -2 … 4- using fixing agent → Parts catalogue. –  Tighten the threaded pin -1- –  Fit the camshaft hub.

–  Tighten securing bolt -1- to 100 Nm (use counter holder -T10051-).

–  Move the camshaft wheel onto the hub. l  The cogged part of the camshaft cogwheel should face upwards. –  Screw in the bolts -1- without tightening. –  Immobilise the hub using the retention tool -T20102-. –  Install toothed belt and adjust valve timing → Chapter. –  Install cylinder head cover → Chapter. –  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 → Fig.   Note Carry out an engine oil change if this is dirty → Booklet602. –  Fill up coolant → Chapter. –  Perform test drive and interrogate fault memory → Vehicle diagnostic, testing and information system VAS 5051 Tightening torques

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 thread locking fluid → Parts catalogue