SEAT Workshop Service and Repair Manuals

Fitting (adjusting the valve timing)   Note t  The toothed belt may only be adjusted on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature. t  If the tensioning roller is to be renewed, the engine bracket must be removed → Chapter. t  Renew securing bolts for camshaft pulley and high-pressure pump pulley.

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

l  Crankshaft is locked using crankshaft stop -T10050-.   Note Turn camshaft hub with counter-hold tool -T10172- and adapters -T10172/4- until camshaft can be locked in position. Hand-tighten at least one securing bolt -1- before performing the above mentioned procedure.

–  Lock the camshaft using the locking pin -3359-. To do this, insert locking pin through outer free elongated hole into hole in cylinder head.

–  Loosen the hand-tightened bolt again. Bolts -arrows- are fitted but not tightened. It should just be possible to turn the sprocket on the camshaft without axial movement.   Note If necessary, turn hub of high-pressure pump at bolt heads with screwdriver until it can be locked in position.

Positioning hub of high-pressure pump

–  Lock the camshaft hub with locking pin -3359-. To do this, push locking pin into adjustment hole outside toothed belt pulley. Bolts -1- are fitted but not tightened. The high-pressure pump sprocket should still just turn, but there must be no axial movement. –  Turn camshaft sprocket and toothed belt sprocket of high-pressure pump in their elongated holes clockwise to stop.

–  Fit toothed belt in sequence described: 1 -  Crankshaft sprocket 2 -  Tensioning roller 3 -  Camshaft sprocket 4 -  Coolant pump sprocket 5 -  High-pressure pump sprocket 6 -  Idler roller –  Unscrew the securing nut of the tensioning roller and remove the Locking tool -T10265-.   Note

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

–  Carefully turn the eccentric adjuster of the belt tensioner clockwise using an angle screwdriver -T10264-. Indicator -2- must be roughly past the centre of the gap in the base plate (rectifies itself during pretensioning). Ensure that the securing nut -1- does not turn as well. –  Hold belt tensioner in this position. Tighten the tension pulley fixing nut as follows: 20 Nm and turn 45° further

–  Fit counter-hold tool -T10172- as shown. Press counter-hold tool -T10172- in direction of arrow and keep camshaft sprocket in pretensioning position. –  In this position, first tighten the securing bolts -1- of the camshaft sprocket and the toothed belt sprocket of the high pressure pump manually and then to 20 Nm. –  Remove locking pins -3359- and crankshaft stop -T10050-. –  Turn crankshaft at least two rotations in engine direction of rotation and set to just before TDC No. 1 cylinder. –  Place crankshaft stop -T10050- on the crankshaft's toothed belt sprocket again.

–  Now turn crankshaft in engine direction of rotation until crankshaft stop pin -arrow- engages in sealing flange whilst turning.   Note

During the following check, only the camshaft and the crankshaft are locked. It is very difficult to find the securing position of the high-pressure pump hub again. However, a slight deviation -arrow- does not influence the engine operation. –  Check whether: t  Camshaft hub can be locked with locking pin -3359-. t  Tensioner lug is centred or a max. of 5 mm to the right of the slot on the base plate. If hub on camshaft cannot be locked: –  Pull crankshaft stop -T10050- back until pin uncovers hole. –  Turn crankshaft out slightly past TDC by turning it in the opposite direction of engine rotation. –  Now turn crankshaft slowly in direction of engine rotation until camshaft hub can be secured in position. –  After locking, loosen securing bolts of crankshaft toothed belt sprocket. If pin of crankshaft stop -T10050- is on left side of bore:

–  Turn crankshaft in engine direction of rotation until crankshaft stop pin engages in sealing flange whilst turning. –  Tighten securing bolts of camshaft toothed belt sprocket hand-tight at first and then to 20 Nm. If pin of crankshaft stop -T10050- is on right side of bore: –  Turn crankshaft slightly counter to engine direction of rotation again. –  Turn crankshaft in engine direction of rotation until crankshaft stop pin arrow engages in sealing flange whilst turning. –  Tighten securing bolts of camshaft toothed belt sprocket hand-tight at first and then to 20 Nm. Continuation –  Remove locking pin -3359- and crankshaft stop -T10050-. –  Turn crankshaft at least two rotations in engine direction of rotation and set to just before TDC No. 1 cylinder. –  Repeat check. –  If camshaft hub can be secured in position, tighten securing bolts as follows:

t  Camshaft gear: Turn 45° further. Counterhold using counterhold tool -T10172- and adapters -T10172/4-. –  Install middle and lower toothed belt guards. –  Fit the vibration damper/pulley: Tightening torque: 10 Nm + turn 90° further –  Install poly V-belt → Chapter. –  Install upper toothed belt guard. Further assembly is basically the reverse of the dismantling sequence. Note the following: t  Ensure that fuel hose connections are tight. t  Do not interchange supply line and return line (return line blue or with blue marking, supply line white). –  Mount the wheel housing moulding. –  Install noise insulation → General body repairs, exterior; Rep. gr.50.