SEAT Workshop Service and Repair Manuals

Camshaft seal: removing and fitting t  Removing → Anchor t  Fitting → 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 -T10051-, see equivalent → Anchor

t	Extractor -T10052-, see equivalent → Anchor

t	Camshaft assembly tool -T40094A-,see equivalent → Anchor

t	Puller -T40095-, see equivalent → Anchor

t	Puller -T40096-, 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 t  Silicone sealant → Spare parts catalogue t  Electric drill with plastic brush attachment t  Protective glasses t  Sealant for joints → Spare parts catalogue

Removing l  Cylinder head installed. –  Remove engine cover panel -arrows-. –  Take toothed belt off camshaft and high-pressure pump → Chapter. –  Remove air cleaner housing → Chapter.

–  Remove crankcase breather hose -2-, press release buttons for this. –  Remove air intake hose. To do this, loosen hose clip -1-. –  Remove cylinder head cover → Chapter

–  Remove bolts -1, 3-; exhaust gas recirculation cooler remains installed.

–  Remove bolts -1- and detach camshaft sprocket.

–  Counterhold hub with counterhold -T10051- and loosen securing bolt -1- of hub. –  Unscrew bolt approx. 2 turns.

–  If it is not possible to take off the hub by hand: –  Attach puller -T10052- and align with openings in hub, tighten mount bolts-1- on hub. –  Counterhold on hexagon flats (30 mm) of puller and screw in bolt -2- to pull off camshaft hub.   Note During this step, hold the extractor tool with a 30 mm wrench. –  Detach hub from taper of camshaft. –  Remove exhauster pump → Rep. gr.47.

–  Unscrew the securing bolts of the bearing cap module in the following sequence -24 ... 1-. –  Remove the bearing cap module. –  Mark fitting location of camshafts for re-installation and remove. Installing l  Tightening torque → Chapter „Valve system: Assembly overview“   Caution Make sure axial bearings in retaining frame are not damaged. The camshafts MUST be installed using the camshaft fitting tool -T40094- as described in the following.

–  Remove the remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine.   WARNING Protect eyes against injuries. Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease. –  Oil running surfaces of both camshafts.

Set up camshaft fitting tool -T40094- as follows: –  Secure supports -T40094/9- and -T40094/10- (with -T40094/11-) to base plate, as shown in the figure. If necessary, remove the supports screwed on here.

–  Fit support -T40094/1- onto position -F- and support -T40094/2- onto position -A-.

–  Place inlet camshaft in supports -T40094/1- and -T40094/2-. –  Turn inlet camshaft in such a way that it can be locked in „TDC“ position using locking device -arrow 1-. l  Recess -arrow 2- for cylinder head bolt must face outwards.

–  Place exhaust camshaft in supports -T40094/9- and -T40094/11-. –  Lock exhaust camshaft with top section -T40094/11-. l  The lug -1- on the top section must engage in the slot -2- in the camshaft, –  Place clamping tool -T40096/1- on the splines of the exhaust camshaft in such a way that each side of the tensioning tool engage on the two halves of the gear. l  The wider arm must engage in the wider half of the gear. –  Tighten the clamping tool using the knurled wheel so that the faces of the gear teeth are in alignment. –  Slide inlet camshaft towards exhaust camshaft, until gear teeth engage -arrows-.

–  Fit the bearing cap module on the camshaft. l  All camshaft bearings must be seated on the camshafts. –  Position camshaft insert tool -T40095- and fix camshafts in position in bearing cover module, as shown in illustration. –  Detach top section -T40094/11-.   Note

Note the use-by date of the sealant. –  Cut off tube nozzle at upper marking (nozzle Ø: approx. 2 mm).

Caution Make sure excess sealant does not contaminate camshaft bearings. Do not apply sealant beads thicker than specified. –  Apply beads of sealant onto clean sealing surfaces of cylinder head as shown in illustration. l  Thickness of the sealing paste bead: 2 ... 3 mm. –  Take camshafts together with retaining frame, camshaft fitting tool -T40095- and clamping tool -T40096/1- out of camshaft fitting tool -T40094- and insert components carefully into cylinder head.

–  Screw in retaining frame bolts in the sequence -1 ... 24- evenly by hand until they make contact. l  The retaining frame should make contact with the cylinder head over the full surface –  Tighten bolts → Fig.. –  Remove clamping tool -T40095- and camshaft fitting tool -T40096/1-. Reassembly is carried out in the reverse order; note the following: –  Renew camshaft oil seal → Chapter. –  Using a suitable drift, knock new sealing cap (core plug) → Item in cylinder head until flush. –  Install exhauster pump → Rep. gr.47. –  Install cylinder head cover → Chapter.   Caution Avoid damage to valves and piston crowns after working on valve gear. t  Because hydraulic compensation elements have to settle, engine must not be started for approx. 30 minutes after installing camshafts. t  Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.