SEAT Workshop Service and Repair Manuals

Removing, installing and tensioning toothed belt 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	Hose clamp -3359-, 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

Removing   Note Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.

–  Disconnect the engine cover-arrow-.

–  Loosen quick-type locks -1 and 2-, and remove front noise insulation. –  Remove the front bumper trim → Rep. gr.63. –  Move lock carrier to service position → Rep. gr.50.

–  Open clips -arrows- and remove toothed belt cover.   Caution If the poly V-belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of operation of poly V-belt with chalk or felt-tipped pen in preparation for re-installation. –  Pivot the tensioner in -Direction of arrow-, remove the poly-V belts from the generator pulley and release the tensioner. –  Take off poly V-belt.

–  Unscrew the bolts -Arrows- of the vibration dampers. Also, counterhold the vibration damper to the middle bolt with a ring spanner. –  Remove vibration damper.

–  Remove centre and bottom sections of toothed belt cover -Arrows-.

–  Place the engine on the TD and stop the crankshaft sprocket with the Crankshaft immobiliser -T10050-. To do so, insert the counterhold in the gear teeth at the front of the timing belt wheel.   Note The mark of the crankshaft sprocket -2- must correspond with the mark of the Support tool-1-. The pin of the crankshaft immobiliser -T10050- must fit in the sealing flange hole.

–  Lock the hub of the camshaft with the Counterholder -3359-. Insert the locking pin through the outer free elongated hole in the opening in the cylinder head. l  The toothed segment -arrow- should point upwards. –  Loosen the bolts -1- that hold the camshaft wheel.

–  Unscrew mounting bolts -1- for toothed belt sprocket on high pressure pump with socket wrench XZN 10 -T10385-approx. 90°.

–  Loosen the securing nut -1- of the tensioning roller. Turn the eccentric adjuster of the tensioning roller with the Socket wrench -T10264- anti-clockwise -Arrow- until tensioning roller can be stopped with the Locking pin -T10265-.   Note t  Ensure that threaded stud is seated tightly. t  If the threaded stud with threaded mounts is loose, tighten it against the stop.

–  Next turn the off-centre adjustment in the direction of the -arrow- as far as possible and hand tighten the fastening nut -1-.   Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of operation of poly V-belt with chalk or felt-tipped pen in preparation for re-installation. –  Take off the toothed belt first from idler roller and then from the remaining toothed wheels. Fitting (adjusting the valve timing) Installation is carried out in reverse order. The following should be taken into account:   Note t  Adjustment work on toothed belts must be performed only on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature. t  Renew securing bolts for camshaft pulley and high-pressure pump pulley.   Caution Risk of damage to valves and piston heads. The crankshaft must not be at „TDC“ at any cylinder when the camshaft is turned.

l  Tensioning roller must be locked with locking tool -T10265- and secured to right stop.

l  The crankshaft is locked using the Immobiliser -T10050-.   Note If required, turn the hub of the camshaft with the Counterholder -T10172- and the Adapters -T10172/4- till they can be locked. Hand-tighten at least one securing bolt -1- before performing the above mentioned procedure.

l  The hub of the camshaft is arrested by the counter holder -3359-. l  Bolts -1- are fitted but not tightened. l  It should just be possible to turn the sprocket on the camshaft without axial movement.   Note -Arrow- can be disregarded.

l  The hub of the high pressure pump is arrested by the counter holder -3359-. l  Bolts -1- are fitted but not tightened. l  The high-pressure pump sprocket should still just turn, but there must be no axial movement.   Note If required, turn the hub of the high pressure pump with a screwdriver on the bolt head till they can be locked.

Position the hub of the high pressure pump.

–  Turn the camshaft sprocket and the toothed belt sprocket of the high pressure pump in their elongated holes in the clockwise direction. –  Fit toothed belt in sequence described: 1 -  Crankshaft gear 2 -  Tensioning roller 3 -  Camshaft sprocket 4 -  Coolant pump sprocket 5 -  High-pressure pump sprocket 6 -  Guide roller

–  Unscrew the securing nut of the tensioning roller and remove the Locking tool -T10265-.   Note -Arrow- can be disregarded.   Note

Check that the tensioning roller is seated properly in rear notched belt guard -arrow-.

–  Connect the counterhold -T10172- as shown. Press the counter holder -T10172- in the -direction of the arrow -and hold the camshaft wheels under tension. –  Tighten the mounting bolts -1- for the cam shaft sprocket and the bolts -2- for the toothed belt sprocket on the high pressure pump in this position. l  Tightening torque: 20 Nm.

–  Turn the eccentric adjuster of the tensioning roller with the Allen wrench -T10264- in the clockwise direction till the pointer -2- is above the centre of the opening of the base plate (is corrected when creating pre-stress). l  Nut -1- must not turn. –  Hold tensioning roller in this position and tighten nut. l  Tightening torque: 20 Nm and 45º (1/8 turn) –  Remove the counter holder -3359- and the immobiliser -T10050-. Checking valve 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“.

–  Attach thecrankshaft stop -T10050- to the toothed belt sprocket on the crankshaft again. –  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 be possible to arrest the cam shaft hub with the crankshaft stop -3359-.   Note Disregard: -item 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. Re-adjust valve timing if requirements are not met → Anchor. If requirements are met, continue with procedure after adjusting valve timing correctly as described below → Anchor. Re-adjusting valve timing: If hub on camshaft cannot be locked: –  Move the crankshaft stop -T10050- back until the journal releases the opening. –  Turn crankshaft in opposite direction of engine rotation slightly past „TDC“. –  Now slowly the crankshaft in the direction of the engine rotation till the hub of the camshaft can be locked. –  After the camshaft is locked, loosen the securing bolts of the toothed belt sprocket of the camshaft. A -The pin on the counter holder -T10050- is located to the left of the opening:

–  Turn crankshaft in direction of engine rotation until pin of crankshaft stop engages in sealing flange as crankshaft rotates. –  Tighten the mounting screws on the toothed belt sprocket for the cam shaft to a torque of 20 Nm. A -The pin on the counter holder -T10050- is located to the right of the opening: –  Turn crankshaft slightly opposite engine direction of rotation. –  Turn crankshaft in direction of engine rotation until pin of crankshaft stop engages in sealing flange as crankshaft rotates. –  Tighten the mounting screws on the toothed belt sprocket for the cam shaft to a torque of 20 Nm. Procedure after adjusting valve timing correctly: –  Remove the Retention tool -3359- and the Crankshaft immobiliser -T10050-. –  Turn crankshaft two rotations in direction of engine rotation by turning bolt for crankshaft sprocket until crankshaft is just before „TDC“.(PMS). –  Repeat check → Anchor. –  If the hub of the camshaft can now be locked, tighten the bolts again as follows:

t  If it is now possible to arrest the cam shaft, tighten bolts -1- for toothed belt sprocket on cam shaft to final torque. t  Tighten bolts -2- for toothed belt sprocket on high pressure pump to final torque. t  Toothed belt cover: Install the lower and centre sections. t  V-belt / vibration damper tightening torque: 10 Nm 90° (1/4 turn) t  Install poly V-belt → Chapter. t  Install the upper toothed belt cover. t  Install the front cover of the bumper → Rep. gr.63. t  Further assembly is basically the reverse of the dismantling sequence. In the process, note the following: t  Ensure that fuel hose connections are tight. t  Do not mix up the feed and return lines (return line blue or with blue marking, feed line white). Tightening torques

Component	Nm
Notched belt tensioning roller on cylinder head	20 + 45° 1)
High pressure pump sprocket on hub	20 + 90º
Camshaft pinion to bin	25
Toothed belt cover (bottom and centre section) to cylinder block	10 3)
Vibration damper	10 + 90° 1) 2) 4)
l  1) 45° (1/8 turn) l  2) 90° (1/4 turn) l  3) Apply locking fluid when installing; for locking fluid, refer to → Parts catalogue. l  4)Replace