SEAT Workshop Service and Repair Manuals

Camshaft: removing and fitting t  Removing → Anchor t  Fitting → Anchor t  Specified torques → 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	Torque wrench -SAT 8010-, see equivalent → Anchor.

t	Hose clamp -T10051-, see equivalent → Anchor

t	Extractor -T10052A-, see equivalent → Anchor

t	Extractor -T10262-, see equivalent → Anchor

t  Wrench -T10310-, see equivalent → Anchor

t  Hose clamp -T20102-, see equivalent → Anchor Removing l  Cylinder head installed. –  Dismount the air filter casing with the air mass meter and the connecting pipe. –  Remove the exhaust gas recirculation radiator and the bypass flap → Chapter –  Remove the exhaust gas recirculation radiator support. –  Remove the notched belt: vehicles with small engine support → Chapter; vehicles with large engine support → Chapter –  Removing the tandem pump → Chapter.   Note The hoses can remain connected on the tandem pump.

–  Extract the retention tool -T20102-. –  Unscrew the bolts -arrows- of the camshaft wheels. –  Remove the camshaft wheels from the hubs.

–  Loosen the fastening bolt-1- of the hub in the camshaft by approx. 2 turns, using the retention tool -T10051-.

–  Fit the extractor -T10052A- to the supply cam hub and tighten the bolts -arrows- on the hub. –  Remove the hub, hold the hexagonal (30 mm) of the extraction tool -T10052A- and tighten the bolt -1- evenly until the hub comes away from the camshaft cone.

–  Fit the extractor -T10052A- to the supply cam hub and tighten the bolts -arrows- on the hub. –  Extract the hub, hold the nut (e/c 30) on the extractor and tighten the bolt -1-. –  Removing the cylinder head: vehicles with engine codes AZV, BKD → Chapter, vehicles with engine codes BMN → Chapter

–  Unscrew the retention nuts -2- of the adjustment bolts -1- on all injector pump units. –  Unscrew the adjustment bolts until the corresponding roller rocker arm sits on the injector pump unit follower spring.

–  Unscrew bolts -1-, -3- and -5-. –  Loosen the bolts -2- and -4- alternately in several steps and unscrew them.   Note Do not extract the rocker arm shaft bolts because the parts are secured on the shaft. Mark the rocker arm correspondence. –  Remove rocker shaft –  Unscrew the upper bolts → Item of the rear timing belt protector. –  Dismount the exhaust gas recirculation radiator (it is not necessary to disconnect the coolant hoses) and leave to one side.

–  Unscrew the upper bolt -arrow- of the bypass valve support and of the exhaust gas recirculation radiator. –  Evenly loosen the remaining 15 bolts (from the outside to the inside) of the bearing cap module.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Disconnect the centre connector for the injector pump units and the glow plugs.

–  Detach electrical connectors from glow plugs -A- and from the unit injectors -B-.   Caution Only slacken or tighten the bolts at the retaining clips when removing the electrical wiring harness. When disconnecting the set of electric cables, this deforms itself and causes play that may lead to cracks in the wiring. –  Remove the bolts -arrows- on the retaining clips and place the entire electrical wiring harness aside.

–  Unscrew remaining 15 bolts for bearing frame evenly, working from the outside inwards. –  Unscrew the 15 mm pressing-out bolts on the rack -T10262- anti-clockwise by hand as far as the stop.

Fitting the frame -T10262-. –  Fit the frame -T10262- on the bearing cap module as shown and tighten the 10 mm bolts to 10 Nm. –  Screw in the pressing-out bolts clockwise by hand until they make contact with the cylinder head bolts. –  Screw the pressing-out bolts evenly in the sequence 1 ... 4 (numbers are inscribed on the bolt heads) until the bearing frame detaches from the cylinder head. –  Remove the bearing frame.   Note t  Do not mix up the half-bearings of the camshafts. t  Mark the camshaft half-bearing correspondence using a water resistant marker on the rear face. –  Extract the camshafts.

Fitting   WARNING Wear eye protection. –  Remove sealant residue from bearing frame and cylinder block with rotating plastic brush or similar. –  Clean the contact surfaces; they must be free from oil and grease.

–  Check if the crankshaft is in TDC position. l  The sprocket of the crankshaft journal must be determined in the PMS of cylinder 1 using the crankshaft stop -T10050- for engines with round sprocket for the crankshaft journal or with the crankshaft stop -T10100- for engines with oval sprocket for the crankshaft journal.   Note t  When installing the camshafts, the cams of cylinder 1 should be pointing upwards. t  Do not mix up the half-bearings of the camshafts. t  When fitting the camshaft, ensure that the half-bearing retaining lugs on the bearing cabs and the cylinder head are correctly seated. t  Seal the contact surface between the bearing cap module and the cylinder head with silicon sealant -D 176501 A1-. –  Remove sealant remaining on the bearing cap module and the cylinder head (with rotating plastic brush or similar). –  Clean sealing surfaces; they must be free of oil and grease. –  Oil the camshaft contact surfaces.

–  Fit the camshaft in TDC position for cylinder 1: l  On both camshafts the cams -1- and -2- of cylinder 1 must face upwards. l  The grooves -arrows- in the camshafts must also point upwards.

–  Cut nozzle off tube at front marking (Ø nozzle diameter: approx. 2 mm).

–  Apply silicon sealant D 176501 A1- → spares catalogue on the clean sealing surface of the bearing cap module -arrows-. l  Thickness of the sealing paste bead: 2 mm.   Note The bearing cap module should be fitted within 5 minutes following the application of the silicon sealing paste. –  Assemble the bearing cap module and the rocker arm shaft.

–  Evenly tighten the bolts -1 ... 20- from the inside towards the outside. Tightening torques: 20 Nm –  Turn bolts -1-, -3-, -5-, -7- and -9- of rocker arm shaft 90° (1/4 turn) further. –  Connect main connector for unit injectors and glow plugs. Installation is carried out in the reverse order of removing, when doing this note the following. –  Fit the camshaft seals → Chapter. –  Install the toothed belt (adjusting valve timing): vehicles with small engine support → Anchor; vehicles with large engine support → Anchor –  Mount the pre-wiring for injector-pump and spark plugs → Chapter. –  Install vibration damper → Chapter. –  Install poly V-belt → Chapter. –  Fit the tandem pump → Chapter. –  Adjust the injector pump units → Chapter. –  Fit the cylinder head: vehicles with engine codes AZV, BKD → Chapter, vehicles with engine codes BMN → Chapter   Note t  After fitting the camshafts, the engine must not be started until after at least 30 minutes. The hydraulic followers must be allowed to sit in to position (otherwise, the valves will hit the pistons). t  After carrying out work on the valve control, rotate the engine gently 2 times to ensure that, before starting the engine, no valve is down. Specified torques .

Component		Nm
Bearing cap module to cylinder head		20
Rocker arm shaft to cylinder head		20 + 90° → Note → Note
Camshaft hubs		100

1)  Replace bolts 2)  90º is equivalent to a quarter turn