SEAT Workshop Service and Repair Manuals

Installing –  Loosen camshaft sprocket securing bolt a half turn.   Note! Never use setting bar -U-40021- as a counter-hold to loosen and tighten the camshaft. Use counter-hold -T20018-.

–  Place a punch (6 mm Ø) through hole in the rear of the toothed belt guard and release the camshaft sprocket from camshaft taper with a blow from a hammer.

–  Check whether TDC mark on flywheel and reference mark are aligned. Engine removed:

–  Fit adjustment device -U-20010- as shown. –  Set adjustment device to 38 mm -arrow A-. –  Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-. –  Fit toothed belt on crankshaft toothed belt sprocket, injection pump sprocket, intermediate shaft sprocket and tensioning roller (note direction of rotation). –  Fit camshaft sprocket into toothed belt and secure sprocket so that the camshaft can still turn.

–  Tension toothed belt. To do this, turn pin wrench -U-30009/A- clockwise until the notch and the raised point align -arrows-.   Note! If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must never be turned back when it has been turned too far. –  Tighten securing nut to 20 Nm. –  Check TDC mark on flywheel again. –  Tighten camshaft sprocket securing bolt to 45 Nm.   Note! Never use setting bar -U-40021- as a counter-hold to loosen and tighten the camshaft.Use counter-hold -T20018-. –  Remove setting bar -U-40021- from the camshaft and remove pin -U-20003- from injection pump sprocket. –  Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again. –  Check if the TDC mark on flywheel the setting bar on camshaft the pin in injection pump sprocket the tensioning roller setting (notch/raised mark) align/are fitted correctly.

–  If the notch and raised mark are not opposite one another -arrows-, tension thetensioning roller further. To do this, hold tensioning roller tight with pin wrench -U-30009/A-, release securing nut, then turn eccentric clockwise further until the notch and the raised mark are opposite one another and tighten the securing nut to 20 Nm. –  Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again. –  Repeat check. –  Install toothed belt lower guard, vibration damper/belt pulley (note fixing), ribbed belt pulley tensioning roller, coolant pump belt pulley and cylinder head cover. –  Fit engine mounting onto cylinder block and tighten the securing bolt to45 Nm.

–  Install right-hand assembly mounting to engine complete. A → Note = 40 Nm + 1/4 turn (90°) further B = 50 Nm C → Note = 20 Nm + 1/8 turn (45°) further 1)  Renew   Note! The turning further angle can be measured with protractor -T20030-. –  Install cover for intake pipes → Chapter, Dismantling and assembling intake pipes. –  Install intake pipe between air cleaner and throttle valve housing using pliers -T20029- for spring-type clips. –  Install upper toothed belt guard.

–  Install pendulum support free of stress. A = 50 Nm (tighten on nut) B → Note = 20 Nm + 1/4 turn (90°) further 2)  Renew   Note! The turning further angle can be measured with protractor -T20030-. –  Install ribbed belt → Chapter. –  Checking injection pump commencement of delivery: → Chapter