SEAT Workshop Service and Repair Manuals

Removing –  With the ignition switched off disconnect battery earth strap. –  Remove upper engine protection assembly. –  Remove air filter. –  Remove upper part of toothed belt guard. –  Remove the cylinder head cover. –  Remove the threaded gearbox cap.   Note! To remove threaded cap from gearbox, use tool -U-20020-.

–  Turn crankshaft to TDC No.1 cylinder -arrow-. Position of the TDC with the engine removed.

–  By the flywheel side, screw the -U-20010- tool into the threaded hole (intake side). –  Fix the measuring bar of the tool, so that the value of 31mm reads in the scale. –  Rurn the flywheel until the mark on the wheel coincides with the end of the rule. The TDC will be situated at this point.

–  Immobilize camshaft with adjusting rule -T20038-. –  The adjusting tool should be centred as follows: –  Once camshaft is immobilized turn it until an extreme of the rule touches the cylinder head. –  Measure the play that results on the other extreme of the ruler with a feeler gauge. –  Insert a feeler gauge with the play reduced halfway between rule and cylinder head. –  Next, turn camshaft so that the rule rests on the feeler gauge. –  Insert a second feeler gauge of the same size in the other extreme, between the rule and the cylinder head.

–  Immobilize injection pump toothed wheel with tool -U-20003-. –  Loosen the toothed belt, to do this loosen the fixing bolt on the tensioning roller, and with the help of tool -U-30009A- turn it to the left. –  Remove the idler roller and partially withdraw the toothed belt.   Note! Mark the turn direction of the toothed belt if it is to be re-used. –  Loosen the tensioning roller of the toothed wheel of the injection pump, using the -T20018A- tool.

–  Use extractor -T20119- to separate the toothed wheel from the injection pump. –  Loosen the extractor feet and place it. –  Align the feet to the orifices of the toothed wheel of the injection pump, and tighten them. –  Tension the toothed wheel of the injection pump by tightening the nut of the -T20119- extractor. –  Remove the toothed wheel of the injection pump from its cone, by gently tapping the thread of the extractor with a plastic mallet (holding the wheel so that it does not fall). –  Remove the nut and withdraw the toothed wheel. –  Remove all the supply and return fuel pipes from the pump.   Note! t  To loosen the injector hoses, use spanner -U-40072-. t  Do not change the shape of the injector hoses. t  Cover all orifices with clean cloths. –  Disconnect the cut-off valve/injection start valve connector. –  Disconnect the measuring system connector and remove the connector terminal from its fixing.

–  Unscrew the console's securing bolts -arrows-.

–  Remove the bolt which secures the rear support -arrow-. –  Remove the injection pump.