SEAT Workshop Service and Repair Manuals

Pulley side:

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Engine support bracket, basic set -T40091-

t	Assembly tool -T10478-

t	Assembly tool -T10476-

t	Camshaft clamp -T10477-

t	Extractor tool -T20143/1-

Removal: –  Remove air cleaner housing → Chapter.

–  Unlock and disconnect fuel supply line -1- and breather line -2-. → Fuel supply system - Petrol engines; Rep. gr.20. –  Open line guide -3- and detach hoses. –  Seal lines so that fuel system is not contaminated by dirt. –  Detach clamps -arrows-.

–  Unscrew securing bolt -1- and remove cover -2-. –  Undo and remove bolts -arrows-.

–  Unclip duct from the guard. –  Remove cover -1- and cover -2-.

–  Unscrew plug -arrow- from crankcase. –  Lower lifting platform completely.   Note t  The lifting platform must be lowered completely in order to allow for screwing the locking pin -T10340- into the crankcase. t  When the vehicle is raised, the hole is hidden behind the drive shaft.

–  Screw locking pin -T10340- into crankcase from above as far as it will go.   Caution If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position! In this case, proceed as follows. –  Unscrew locking pin. –  Turn crankshaft 90° in direction of rotation of engine. –  Screw locking pin -T10340- into crankcase as far as it will go. –  Tighten locking pin -T10340- to 30 Nm. –  Turn crankshaft in direction of rotation of engine as far as the stop. Locking pin -T10340- locks crankshaft in direction of engine rotation.

Marked gap -1- of camshaft adjuster -3- is aligned with lug -2- of camshaft housing.

Marked tooth -1- of exhaust camshaft sprocket -3- is aligned with lug -2- of camshaft housing.   Caution The camshaft clamp -T10477- must slide into position easily. The camshaft clamp must not be positioned using any kind of hammer.

–  Insert camshaft clamp -T10477- to stop into camshafts and tighten bolt -arrow- by hand. –  Remove poly V-belt → Chapter. –  Remove windscreen wiper arms → Electrical system; Rep. gr.92. –  Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50.

–  Fit adapter -10-222A/31-2- onto suspension struts. –  Angle pieces of adapters -arrow- point towards engine compartment.

–  Position support -10-222A/31-5- above bonnet catch. –  Correct position is between 2 lugs -arrow-.

–  Fit support bracket -10 - 222 A- and engine support basic set -T40091- with adapters as shown. –  Support engine on right eye and slightly release load from assembly mounting by turning spindle. –  Disconnect earth wire -1-.

Unscrew securing bolts -arrows- and remove assembly mounting on engine side.

–  Unscrew securing bolts -1- and swivel alternator in -direction of arrow-. –  Lift motor up sufficiently by turning spindle in order to allow for unscrewing securing bolt of engine mounting.

–  Unscrew securing bolts -2- of engine mounting and 3 bolts -1- of lower toothed belt guard.   Caution When loosening and tightening the securing bolts, the camshaft sprockets must in any case be secured with the counterhold -T10172-. The camshaft clamp -T10477- may not be subjected to load when tightening the camshaft sprockets in order to avoid damage to the tool or to the camshafts.

–  Secure camshaft adjuster with counterhold -T10172- and unscrew plug -1-.   Note t  When adjusting the valve timing, both camshaft sprockets must be loose. t  Therefore, even if only one seal is being renewed, both camshaft sprockets must be loosened. –  Secure camshaft adjuster and camshaft sprocket with counterhold -T10172-.

–  Loosen securing bolts -1- and -2-. –  Loosen securing bolt -3- of belt tensioner and release tension of belt tensioner by turning the eccentric -4- (hexagon socket insert) in -direction of arrow-.

–  Remove seal -1- using extractor hook -T20143/1-. Installation –  Put together assembly sleeves -T10478/2- and -T10478/3- in -direction of arrow-.

–  Fit new seal in -direction of arrow- onto assembly sleeve -T10478/2-.

–  Pull off assembly sleeve -T10478/3- in -direction of arrow-. –  Fit assembly sleeve -T10478/2- with seal -1- on camshaft.

–  Draw in thrust piece -T10478/1- to stop with securing bolt of camshaft adjuster -2-.   Note When installing the seal of the exhaust camshaft, bolt -T10478/4- is used for this purpose. –  Adjusting valve timing → Chapter.   Caution After completing work, it is essential to ensure that the locking pin -T10340- and the camshaft clamp -T10477- have been removed. Tightening torque of the cylinder block oil filler neck: 30 Nm Further assembly is basically the reverse of the dismantling sequence.