SEAT Workshop Service and Repair Manuals

Removing, installing and tensioning toothed belts t  Removing → Anchor. t  Fitting (adjusting the valve timing) → Anchor t  Check valve timing → Anchor. t  Correcting the valve timing → Anchor t  Continue with the assembly after setting the correct timing → 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	Diesel injection pump locking pin -3359- (2 pcs), see equivalent → Anchor

t	Hose clamp -T10050-, see equivalent → Anchor

t	counterhold -T10172-, see equivalent → Anchor

t	Spanner -T10264-, see equivalent → Anchor

t	Hose clamp -T10265-, see equivalent → Anchor

t	Socket XZN 10 -T10385-, 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 . –  Remove the engine cover upwards -arrows-. –  Remove front right wheel.

–  Fit the centre noise insulation -fasteners 1 ... 3-.

–  Remove the right wheel housing -Fixing parts 1 ... 3-.

–  Unplug electrical connector -2- on exhaust gas pressure sensor 1 -G450-.   Note Disregard: -Pos. 1-.

–  Disengage fuel hose -2- at bracket. –  Pull retainer for fuel lines off upwards -arrow- and lay to side. –  Disconnect electrical connection -1- on supplementary fuel pump -V393-. –  Unscrew the bolts -3- and remove the holder together with the supplementary fuel pump -V393- and place to the side.

–  Loosen bolt -1-. –  Unscrew bolt -2- and nut -3-. –  Take hose retainer -4- off fuel filter, place fuel filter -7- aside (fuel hoses -5- and -6- remain connected).

–  Unplug the plug connector -3- of the radiator outlet coolant temperature sender -G83-. –  Unscrew nut -1- and bolt -2-. –  Move coolant pipe (right-side) -arrows- to side (hoses remain connected).

–  Remove upper toothed belt cover, release clips -arrows- for this. –  Remove poly V-belt → Chapter. –  Remove vibration damper → Chapter.   Note The poly V-belt tensioner does not have to be locked.

–  Remove bolts -arrows-. –  Remove the centre and rear covers for the toothed belt.   Caution Risk of destruction due to toothed belt jumping. Only turn crankshaft in engine direction of rotation. –  Rotate crankshaft by turning bolt on crankshaft sprocket until camshaft sprocket is positioned at „TDC“.   Note t  The camshaft sprocket is shown without toothed belt in the following figures to provide a better view. t  Disregard: -Pos. 1-.

l  The toothed segment -arrow- should point upwards. –  Lock the camshaft hub using the diesel injection pump locking pin -3359-.

–  Immobilise the notched belt crankshaft sprocket, with the puller -T10050-. l  The markings on the sprocket -2- and the crankshaft stop -1- must align -arrow-. The pin of the crankshaft stop must engage in the aperture in the sealing flange.   Note Crankshaft stop can only be pushed onto toothed belt sprocket from face end of splines.

–  Loosen the bolt -1- of the gear pinion camshaft by about 90°.   Note Disregard -arrow-.

–  Remove bolt -1- for coolant pipe. –  Loosen the bolt -2- of the gear pinion high pressure pump by approx. 90° using the socket XZN 10 -T10385-.

–  Loosen nut -1- for tensioning roller. –  Turn the cam of the tensioning roller to the left using the wrench -T10264--arrow-, until the tensioning roller can be locked using the pinning tool -T10265-.

–  Then turn the cam of the tensioning roller to the right until the end using the wrench -T10264--arrow- and tighten the nut -1- by hand.   Caution Risk of irreparable damage if direction of rotation is reversed on previously used toothed belt. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen for re-installation. –  Remove toothed belt first from idler roller and then from remaining toothed belt pulleys. Fitting (adjusting the valve timing) l  Specified torques → Chapter.   Note Perform adjustments on toothed belt only when engine is cold.   Caution Avoid damage to valves and piston crowns. The crankshaft must not be at „TDC“ at any cylinder when the camshaft is turned. Preconditions:

l  The tensioning roller is locked together with the pinning tool -T10265- and fixed to the right stop with the nut.

l  The hub of the camshaft is locked using the pinning tool -T10265-. l  Loosely tightened bolts -1-. l  The gear pinion of the camshaft can still be turned and should not be tilted any more.   Note Disregard -arrow-.

l  Crankshaft is locked using crankshaft stop -T10050-.

l  The hub of the high pressure pump is locked using the pinning tool -T10265-. l  Loosely tightened bolts -1-. l  The gear pinion of the high pressure pump can still be turned and should not be tilted any more.   Note

If necessary, apply a screwdriver to bolt heads -1- and turn the high-pressure pump hub until it can be locked with the locking pin.

–  Turn the gear pinion of the camshaft and the high pressure pump to the right until the end. –  Fit toothed belt in sequence described: 1 -  Crankshaft gear 2 -  Tensioning roller 3 -  Cogwheel for timing belt 4 -  Gear pinion of the coolant pump 5 -  Gear wheel of the high-pressure pump 6 -  Guide roller

–  Loosen the nut -1- of the tensioning roller and remove the pinning tool -T10265-.   Note Disregard -arrow-.   Note

Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-.

–  Place the support tool -T10172- on the pinion gear of the camshaft, as shown in the figure. –  Apply force to counterhold tool in anti-clockwise direction -arrow- and maintain tension. –  Tighten the bolts -1- of the camshaft pinion gear and the bolts -2- of the high pressure pump pinion gear to this position. l  Specified torque: 20 Nm.

–  Carefully turn the cam of the tensioning roller to the right using the wrench -T10264- until the pointer -2- is positioned in the middle in the gap of the base plate. l  Nut -1- must not turn. –  Hold tensioning roller in this position and tighten nut. –  Remove the retention tool -3359- and the crankshaft positioning device -T10050-. Checking distribution timing   Caution Risk of destruction due to toothed belt jumping. Only turn crankshaft in engine direction of rotation. –  Turn crankshaft two rotations in direction of engine rotation by turning bolt for crankshaft sprocket until crankshaft is just before „TDC“.

–  Place the crankshaft positioning device -T10050- on the crankshaft sprocket of the toothed belt. –  Then turn the crankshaft in direction of engine rotation until the pin -arrow- on the crankshaft stop engages in the sealing flange as the crankshaft rotates.

l  It should now be possible to lock camshaft hub with diesel injection pump locking pin -3359-.   Note Ignore positions -1- and -arrow-.

l  It is very difficult to reproduce the locking position of the high-pressure pump hub. However, a slight deviation -arrow- does not influence the engine operation.

l  Pointer -2- on tensioner roller must be centred between tabs -1- and -3- on base plate.   Note The maximum permissible sideways deviation from the specified position is 5 mm. t  Re-adjust valve timing if requirements are not met → Anchor. t  If requirements are met, continue with procedure after adjusting valve timing correctly as described below → Anchor. Correcting the valve timing: –  If camshaft hub cannot be locked, withdraw crankshaft stop -T10050- until pin is clear of bore. –  Turn crankshaft in opposite direction of engine rotation slightly past „TDC“. –  Now turn crankshaft slowly in direction of engine rotation until it is possible to lock camshaft hub. –  Loosen bolts for camshaft sprocket after locking hub.

A - The pinion of the crankshaft stop -T10050- is located to the left of the borehole: –  Turn crankshaft in direction of engine rotation until pin of crankshaft stop engages in sealing flange as crankshaft rotates. –  Tighten camshaft sprocket bolts to 20 Nm. A - The pinion of the crankshaft stop -T10050- is located to the right of the borehole: –  Turn crankshaft slightly in opposite direction to engine rotation. –  Turn crankshaft in direction of engine rotation again until pin of crankshaft stop engages in sealing flange as crankshaft rotates. –  Tighten the bolt 1 of the gear pinion camshaft by approx. 20 Nm. Continue with the assembly after setting the correct timing –  Remove the retention tool -3359- and the crankshaft positioning device -T10050-. –  Turn crankshaft two rotations in direction of engine rotation by turning bolt for crankshaft sprocket until crankshaft is just before „TDC“. –  Repeat check → Anchor.

–  When the hub of the camshaft can be locked, fully tighten the bolt -1- of the gear pinion camshaft → Item. –  Fully tighten the bolt -2- of the gear pinion of the high pressure pump → Chapter. –  Check the valve timing once more → Anchor. Perform further installation in reverse order, paying attention to the following:   Note t  Renew seals and gaskets. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install vibration damper → Chapter. –  Fit the sound proofing sump → Exterior body installation work; Rep. gr.50 –  Install coolant pipe (right-side) → Chapter. –  Install fuel filter → Chapter. –  Fit the supplementary fuel pump -V393- → Chapter.