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	Spanner -T10070-, see equivalent → Anchor

t	Extractor -T40039-, see equivalent → Anchor

t	Torque wrench -V.A.G 1331-, see equivalent → Anchor.

t	Torque wrench -V.A.G 1332-, see equivalent → Anchor.

t	Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor

t	Tray -VAS 6208-, see equivalent → Anchor

Removing   Note During assembly, all the cable ties that are released or cut must be placed in the same position.   Caution When disconnecting battery, observe safety measures → Electrical system; Rep. gr.27. –  Disconnect earth wire at battery with ignition switched off. –  Drain coolant → Chapter. –  Place the lock carrier plate into service position → Bodywork, exterior fitting work; Rep. gr.50 –  Remove coolant pipe (top) → Chapter. –  Remove intake manifold → Chapter. –  Remove the timing belt from the cogwheel of the camshaft → Chapter. –  Remove the air filter housing → Chapter.

–  Remove crankcase breather pipe -2-. –  Detach crankcase breather hose from cylinder head cover. –  Remove the pipe -1- at the combination valve for secondary air, from the cylinder head cap and the thermal shield-3-. –  Pivot secondary air pipe slightly to the side. –  Remove heat shield.

–  Remove bolts -1- and -2- on oil supply pipe. –  Unscrew bolts -3- for turbocharger.

–  Separate the plug connections -arrow- of the valve 1 for cogwheel adjustments -N205-.

–  Unplug electrical connector -arrow- at coolant temperature sender.

–  Disconnect vacuum hose -arrow- at combination valve for secondary air. –  Remove coolant flange by unscrewing bolts -2- and -3-. –  Unbolt bracket -1- for oil supply pipe.   Note For improved understanding, it is shown from the rear in the illustration with engine removed. –  Unclip/release all electrical wires on the cylinder head and move clear. –  Detach coolant hose for heat exchanger of the heater at the rear of cylinder head (release retaining clip on connecting flange).

–  Unscrew the earth wire -2-. –  Unplug the electrical connectors -3- and move wiring clear. –  Pull out ignition coils -1-.   Note

Remove ignition coils using the extractor -T40039-.

–  Remove the nuts -arrows- and detach the cylinder head cover. –  Detach both oil deflectors.

–  Remove cylinder head bolts in the sequence: -1 ... 10-. –  Remove the cylinder head with the assistance of a 2nd mechanic. Installing   Note t  Cylinder heads which have cracks between the valve seats or between valve seat inserts and the spark plug thread can be used further without reducing service life, provided the cracks do not exceed a maximum of 0.3 mm in width, or when no more than the first 4 turns of the spark plug threads are cracked. t  Renew the cylinder head bolts. t  When performing repair work, renew self-locking nuts and bolts. t  Renew bolts which have a specified tightening angle, as well as seals and gaskets. t  Carefully remove any sealant residue from the cylinder head and cylinder block. See that it does not cause any grooves or scratches. 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  When installing a reconditioned cylinder head with camshafts fitted, the contact surfaces between bucket tappet and cam surface must be lubricated after fitting the head. t  The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the cylinder head. t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted. t  Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks. t  When replacing the cylinder head or cylinder head gasket, the old coolant must also be replaced. t  Secure all screw joints with serial hose clips → Spare parts catalogue. t  Fit the cable clamps in the same position as they were.

–  Set camshaft to TDC -top arrow- before fitting cylinder head. –  Make sure that crankshaft is in TDC position -bottom arrow-; turn crankshaft via toothed belt sprocket bolt if necessary.

–  Unscrew bolts -1- and -2- on turbocharger bracket (about 2 full turns each) to avoid stressing when installing the cylinder head.

–  Place cylinder head gasket in position. l  Note position of centring pins in cylinder block -arrows-. l  Observe correct installation position of the cylinder head gasket. Identification feature: the component no. must be legible from the inlet side. –  Fit cylinder head. –  Insert new cylinder head bolts and tighten hand-tight.

–  Tighten the cylinder head screws in three steps and in the following sequence:

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

Note Cylinder head bolts do not have to be torque down again later after repair work. The remaining installation steps are carried out in reverse sequence - note the following points: –  Secure turbocharger with new gasket to exhaust manifold and secure bracket to cylinder block → Chapter. –  Install cylinder head cover → Chapter. –  Install toothed belt (adjust valve timing) → Anchor. –  Install vibration damper → Chapter. –  Install poly V-belt → Chapter. –  Installing intake manifold → Chapter. –  Install coolant pipe (top) → Chapter. –  Install front exhaust pipe together with catalytic converter → Chapter. –  Align exhaust system without tension → Chapter –  Assemble the lock carrier with attachments → Bodywork - Exterior assembly work ; Rep. gr.50.

–  The torque reaction support must set itself on its rubber stop by means of its self weight, then tighten the nuts -arrows-. Tightening torque → Chapter „Assembly mountings - exploded view“ –  Fit the front bumper trim → Bodywork, exterior fitting work; Rep. gr.63. –  Connect battery. For measures required refer to → Electrical system; Rep. gr.27. –  Check oil level → Chapter.   Note If engine oil is contaminated, perform oil change → Booklet301. –  Fill cooling system with fresh coolant → Anchor. –  Check headlight adjustment → Booklet301. Tightening torque

Component		Nm
Turbocharger to exhaust manifold		35 → Remark → Remark
Smear bracket of the	cylinder block	25
Turbocharger to:	Turbocharger	30
Support for	Intake manifold	23
Intake manifold to	Bracket for ancillary mechanical units	23
Stop for torque reaction support to lock carrier		28
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5,5

1)  Renew bolts 2)  Coat thread and contact surface of bolt head with high-temperature paste; → Parts catalogue