SEAT Workshop Service and Repair Manuals

Removing and installing cylinder head t  Removing → Anchor t  Fitting → 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	Adjustment tool -3070-, please see Correspondence → Anchor

t	Diesel injection pump locking pin -3359- (2 pcs), see equivalent → Anchor

t	Hose clamp -T10050-, see equivalent → Anchor

t	Hose clamp -T10051-, see equivalent → Anchor

t	Extractor -T10052A-, see equivalent → Anchor

t	Socket -T10385-, see equivalent → Anchor

t	Torque wrench -VAG 1331-, see equivalent → Anchor.

t	Torque wrench -VAG 1332-, see equivalent → Anchor.

t	Collecting tray -VAS 6208-, see equivalent → Anchor

t	Wrench kit 17 mm -T10395-, see equivalent → Anchor

Special tools and workshop equipment required

t	Socket -10 222A-, see equivalent → Anchor

t	Frame -10 222A/1-, see equivalent → Anchor

t	Adapter -10 222A/3-, see equivalent → Anchor

t	Hook -10 222A/10-, see equivalent → Anchor

Removing   Note t  Before carrying out further work, disconnect battery earth strap. 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. t  All connectors which are separated during disassembly must be reconnected in the original position when installing.   WARNING t  When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines and electrical wiring so that they are in their original positions. t  e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid, vacuum. t  Ensure that there is sufficient clearance to all moving or hot components.   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. gr.27. –  With ignition switched off, disconnect earth cable at battery → Rep. gr.27.

–  Loosen the engine cover at the locations -arrows- and remove.

–  Unscrew the securing bolts -arrows- and remove the engine soundproofing..

–  Remove the front right wheel housing moulding.

–  Loosen the spring-type clip -1- and remove the intake hose. –  Unplug the connector -3- at the solenoid valve for charge pressure control -N75-. –  Unscrew the nut -2- of the charge pressure control solenoid valve -N75-. –  Remove all vacuum lines together with the brackets -5- upwards from the air filter. –  Unplug connector -6- from air mass meter -G70-. –  Remove the bolt -4- from the lower part of the air filter.

–  Unscrew the fixing screws -arrows- of the air intake unit -1-and remove the connecting hose -2- to the air filter. –  Remove the air filter housing together with intake line completely. –  Drain coolant → Chapter.

–  Remove the vacuum line between the vacuum pump and the servo brake -arrow-.

–  For this purpose, remove the vacuum line -arrow 1- from the bracket on the cylinder head. Pre-heater line -arrow 2 - is not necessarily installed. –  Detach connectors . t  -1-Exhaust gas temperature sender 1 -G235- t  -2-Exhaust gas temperature sender 3 -G495- t  -3-Exhaust gas temperature sender 4 -G648-

t  -4-Lambda probe -G39-

–  Disconnect electrical connector -2- at pressure differential sender -G505-. –  Remove bolt -3- from pressure differential sender -G505- bracket. –  Lay pressure differential sender -G505- with lines down to rear.

–  Disconnect the quick connectors -1- and -2-, and collect leaking fuel with a cloth.

–  Disconnect the line from the fuel filter -1- and -2-, press the release tabs for this purpose. –  Catch any fuel coming out.

–  Remove the fuel line with attached bracket upwards from the guide of the coolant expansion reservoir.

–  Remove the cartridge of the fuel filter upwards from the bottom part. –  Unscrew the bolts -arrows-, and remove the bottom part of the fuel filter.

–  Press release tabs and disconnect crankcase breather hose -1-.

–  Unscrew the bolt -arrow- (cannot be lost) and remove the vacuum hose -A- from its bracket in a clockwise direction.

–  Unplug connector -1- at position sender for charge pressure positioner -G581-. –  Remove the vacuum hose -2- of the underpressure capsule from the turbocharger. –  Disconnect vacuum hose -3-. –  Move electrical wiring on turbocharger clear.

–  Unhook the vacuum line -arrows- and set it aside.

–  Disconnect the vacuum lines -arrows-. –  Lay vacuum hoses to side. –  Remove cylinder head cover → Chapter

–  Remove the connection -arrow- from the vacuum line.

–  Unclip the engine pre-wiring from the bracket -arrow-.

–  Unplug the connector -arrow- of intake manifold flap motor -V157-. –  Lay engine wiring to side.

–  Disconnect the connector of the throttle valve control module -J338--2-. –  Open the clip -3- and remove the supercharger air hose. –  Unscrew bolt from oil dipstick connection -4- . –  Drain coolant → Chapter

–  Unplug electrical connector -1- at coolant temperature sender -G62-.

–  Unplug electrical connector -1- at oil pressure switch -F1-. –  Remove bolt -arrow-.

–  Unscrew the screws -2, 5- and -arrow-. –  Move electrical wiring and hoses on the charge air pipe clear. –  Loosen hose clip -3- and detach charge air pipe (left-side).

–  Unscrew bolts -arrows- and remove pulsation damper -2-. –  Carefully press the supercharger air hose to the side as far as possible.   Caution Take care that the separating element of the connecting hose is not bent or stretched excessively. There is a danger of cracking.

–  Separate the underpressure hose -1- on the vacuum pump.   Note Ignore the -arrows-. –  Remove the particulate filter to provide space for removing and fitting the oil supply line with the support of the turbocharger.

–  Remove the hose clip -1- between the particle filter and the exhaust gas turbocharger. –  Unscrew the bolts -4- on top of the particle filter.

–  Remove nuts -2-.

–  This enables the screws to be accessed, that fixes the bracket -arrow- of the oil supply line on the support of the exhaust gas turbocharger. Remove bolt -arrow-.

–  Remove the connecting pipe -A- that returns from the exhaust gas recirculation radiator.

–  Unscrew the bolts -1, 2- and the hollow bolts -4, 5-; rmove the exhaust gas turbocharger bracket together with the oil return hose.   Note Do not observe -item 3-.

–  Remove bolt -arrow- securing rear cover for toothed belt.

–  Release hose clips -1- and -2- and disconnect coolant hoses.

–  Unplug electrical connectors -1- for the hall sender -G40- and detach connectors from retainer.

–  Fit the mount -10 222A- with the necessary adapters and attach as shown in the figure, and retain the motor in its fitting position.   Note t  When removing the bearing, the engine must be secured using the mount -10 222A-. t  The engine mount may only be loosened once the powertrain support assembly has been fitted.

–  Remove nut -1- for earth wire. –  Unscrew the securing bolts from the engine assembly / engine support, engine assembly / body -arrows- and remove engine assembly completely.   Note Disregard position -2-.

–  Unscrew the bolts -1- and -2- of the pendulum support and remove them.   Note t  The mechanical assemblies mounting should only be dismounted with the engine being held via the support -10 222A-. t  The engine mount may only be loosened once the powertrain support assembly has been fitted.   WARNING When raising or lowering the engine with the support -10 222A-, make sure that the components / hoses are not damage, excessively stretched or pulled off. –  Insert the engine as far as possible towards the radiator.   Note Remove the fixing bolts -1 -together with the engine bracket. Lift and lower the engine. Use the spindle of the support bracket -10 222A-, in order to unscrew or position bolts -2- and -3-.

–  Lift the engine and unscrew the bolts -1- and -3-. –  Lower the engine and unscrew the bolt -2-.   Note After unscrewing the three bolts, the engine support cannot be removed any more. The drive chain must have been released for this purpose. –  Slacken the toothed belt and remove from the camshaft and the high pressure pump → Chapter. –  Then the tension rollers for the timing belt can also be removed. –  Re-install the engine mounting using the used bolts by hand and tighten. –  Remove the support -10 222A-. –  Detach camshaft sprocket from hub. –  Detach camshaft hub, remove camshaft hub with the Extractor tool -T10052A-.

–  Counterhold the hub with counterhold tool -T10051- and loosen the securing bolt -1- of the hub. –  Unscrew securing bolt of hub approx. 2 turns.

–  Fit the Extractor tool -T10052A- and align it with the hub holes. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening the Extractor tool-2- until hub separates from taper of camshaft.   Note In this process, use 30 mm wrench to hold puller. –  Remove hub from taper of camshaft.

–  Release the cylinder head bolts in the sequence -1 … 10-.   Note t  A second mechanic is required to remove the cylinder head. t  The toothed belt tensioning roller is detached from the stud when the cylinder head is lifted out. –  Lift cylinder head at gearbox end first and guide out of toothed belt guard. Make sure that toothed belt tensioner does not fall down. –  Take care to place the cylinder head down without bending the oil return line. If necessary, place a block of wood below exhaust manifold.   Caution Risk of damage to glow plugs when putting down cylinder head. After removal, the cylinder head must not be put down on the gasket side with the glow plugs still installed, because the glow plugs project slightly beyond the gasket surface. Fitting l  Tightening torques → Chapter   Caution Avoid damage to sealing surfaces. t  Carefully remove sealant residue from cylinder head and cylinder block. t  Ensure there are no scratches or scrapes caused. Avoid damage to cylinder block. No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block. Risk of leaks at cylinder head gasket. t  Carefully remove any remains of sealant from the cylinder head and cylinder block. Ensure there are no scratches or scrapes caused. 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 gasket with care to avoid damaging the silicon layer or the ridged area of the cylinder head gasket. Avoid damage to 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 crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts as well as seals, gaskets and O-rings. t  Cylinder heads must not be reworked on TDI engines. t  When installing an exchange cylinder head, the contact surfaces between roller rocker fingers and cams must be oiled. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and the coolant in the entire cooling system. –  Before fitting cylinder head, remove crankshaft stop -T10050- and turn crankshaft against normal direction of rotation until all pistons are positioned approximately equally below „TDC“. –  Cylinder head gasket must lie with identification facing upwards.

–  To centre, screw guide pins -3070/9- into outer holes on inlet side.

–  Note cylinder head gasket identification: 1 -  Part No. 2 -  Holes 3 -  Ignore   Note t  If the cylinder head gasket or cylinder head have been replaced, select the new cylinder head gasket according to the number of holes on the old gasket. t  If parts of the crankshaft drive have been renewed, the new cylinder head gasket must be selected by measuring the piston projection at „TDC“ → Chapter. –  Place cylinder head gasket in position. l  Note position of dowel sleeves in cylinder block. l  Installation position of the cylinder head gasket: the word „top“ or the Part No. should face towards the cylinder head. –  Fit cylinder head.   Note Position tensioning roller on studs when fitting cylinder head. –  Screw in 8 cylinder head bolts by hand until they make contact. –  Unscrew guide pins -3070/9- through threaded holes in cylinder head and screw in remaining cylinder head bolts by hand until they make contact. Tightening sequence

–  Tighten bolts in the sequence -1 ... 10- in 4 stages as follows: 1.  Tighten to 30 Nm 2.  Tighten to 50 Nm 3.  Turn 90° further. 4.  Turn 90° further.   Note Cylinder head bolts do not have to be torqued down again. –  Install rear cover for toothed belt, camshaft hub and sprocket → Chapter.

–  Lock the camshaft hub using the diesel injection pump locking pin -3359-.   Note Ignore positions -1- and -arrow-.

–  Lock the high pressure pump using the diesel injection pump locking pin -3359-.   Note Disregard: -Pos. 1-.

–  Turn the crankshaft in the direction of the engine rotation „TDC“ and lock using the crankshaft stop -T10050-. –  Install notched belt (adjusting valve timing) → Anchor. The remaining installation steps are carried out in reverse sequence - note the following points: –  Install cylinder head cover → Chapter. –  Install oil supply line → Chapter. –  Install exhaust gas recirculation pipes → Chapter. –  Install air pipe (left-side) → Chapter. –  Install the guide tube for the dip stick. –  Mount the particle filter → Chapter. –  Install the bracket and battery → Rep. gr.27. –  Install air cleaner housing → Chapter. –  Install support for turbocharger → Chapter. –  Install radiator cowl → Chapter. –  Check oil level → Chapter.   Note Carry out an engine oil change if this is dirty → Booklet601. –  Fill up coolant → Chapter.