SEAT Workshop Service and Repair Manuals

Removing and installing cylinder head t  Removing → Anchor t  Installing → 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	Guide pins -3450-, see equivalent → Anchor

t	Spring retainer -T10358-

t	Socket -U 30025E-, see equivalent → Anchor

t	Torque wrench (5... 50 Nm) -V.A.G 1331-, see equivalent → Anchor

t	Torque wrench (40... 200 Nm) -V.A.G 1332-, see equivalent → Anchor

Removing   Note Engine at tepid temperature at most. –  Remove battery → Electrical system; Rep. gr.27 –  Remove air filter → Chapter. –  Remove valve timing housing → Chapter. –  Remove distribution chain → Chapter. –  Remove camshaft housing → Chapter. –  Remove roller rocker fingers together with support elements and lay aside on a clean surface. –  Ensure that the roller rocker fingers and the support elements are not mixed up. –  Remove the spark plugs using the spark plug spanner -3122 B-.   WARNING Steam may be released when opening the expansion tank. Wear safety goggles and appropriate clothing to avoid injury to eyes and burns. Cover the cap with a cloth and open carefully. –  Open and close expansion tank cap to release pressure in cooling system. –  Drain coolant → Chapter –  Loosen hose clips and pull coolant hoses off the thermostat cover. –  Remove thermostat cover → Chapter.   WARNING Fuel supply pipes are pressurised. Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then eliminate the pressure by carefully separating the pipe.

–  Remove the fuel supply tube -2-. Also press the release tabs. –  Seal lines so that no dirt is able to enter fuel system. –  Observe rules for cleanliness → Chapter. –  Now remove the intake manifold → Chapter. –  Remove the exhaust manifold with catalytic converter → Chapter. –  Remove oil pressure switch -F1- → Item.

–  Unscrew the attachment bolt for the gearbox and tighten the support -T10358-, as shown in the figure. –  Fit the hooks of the support device -U 30025E- to the bracket -T10358-, as shown in the figure. –  Turn the spindle until the hooks are slightly tensioned.

–  Release the hook -1- in the left hand side ring and move the spindle to the left hand side of the support device -U 30025E-. –  Remove the rings → Item.

–  Loosen socket head studs in the sequence given and then remove completely from the cylinder head. –  Carefully remove cylinder head. Installing Install in reverse order to dismantling, noting the following:   Note t  Do not remove new cylinder head gasket from its packing until immediately before installing. 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. –  Also prevent dirt and particles from getting into the coolant. –  Now carefully clean sealing surfaces of 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.

–  Place the new cylinder head gasket over the centralising pins -A-. The inscription (part no.) -B- should be legible. –  Fit cylinder head, insert the 8 cylinder head studs and hand tighten.

–  Tighten the cylinder head studs in the sequence shown in the following: –  Tighten all bolts to 30 Nm. –  Then tighten all bolts 1/4 turn (90°) using a rigid wrench. –  Then tighten all bolts again 1/4 turn (90°).   Note When turning camshaft, crankshaft should not be at TDC. The piston head/valves might be damaged. –  Install camshaft housing → Chapter. –  Install timing chain and drive chain of oil pump → Chapter. –  Adjust valve timing → Chapter. –  Fit distribution casing → Chapter. –  Fill up coolant → Chapter.