SEAT Workshop Service and Repair Manuals

Installation   Note Seal parting surface between retaining frame and cylinder head using silicone adhesive sealant -D 176 501 A1-.   Caution The camshafts may only be installed with the camshaft fitting tool -T40094- as described below. Otherwise the axial bearings in the retaining frame will be destroyed and the cylinder head must be replaced. –  Remove the remaining sealant from cylinder head and bearing cap module, e.g. using a rotating plastic brush or similar.   Caution Make sure that no sealant residues get into the cylinder head or the bearings.

–  Clean sealing surfaces; they must be free of oil and grease. –  Oil the camshaft running surfaces. Set up camshaft insert tool -T40094- as follows:

–  Remove supports -T40094/3-, -T40094/4- and -T40094/5- from base plate. The connection can be accessed from below.   Note If the supports of the camshaft fitting tool -T40094- are not yet marked, mark the removed supports, e.g. with number stamps, so they can be fitted in the original positions later.

–  Instead, position supports -T40094/9- and -T40094/12- on outer positions which have become free. –  Place support -T40094/2- in position „A“. Place support -T40094/1- in position „D“. –  First insert inlet camshaft as shown. Ensure that indentation -arrow- for cylinder head bolt faces »outwards«.

–  Position 0.50 mm feeler gauge. Push support -T40094/8- into inlet camshaft groove.

–  Insert exhaust camshaft, lock via its groove -arrow- with -cover T40094/11-. –  Position clamping tool -T40096/1- on exhaust camshaft sprockets.   Caution Ensure that the clamping jaw marked with an arrow is seated on the wider gear.

–  Tighten clamping tool -T40096/1- using knurled wheel so that faces of gear teeth are in alignment. If necessary use a 13 mm open-ended spanner as an aid: –  Slide inlet camshaft towards exhaust camshaft until teeth engage. –  Fit retaining frame onto camshafts. l  All camshaft bearings must be seated on the camshafts.

–  Fit clamping tool -T40095- as illustrated and fix camshafts in position in the bearing cap module. –  Remove cover -T40094/11-. –  Pull support -T40094/8- out of inlet camshaft groove.

–  Cut off nozzle on tube at front marking (Ø of nozzle approx. 2 mm). –  Apply a bead of sealant (approx. 2 ... 3 mm wide) -arrows- as shown in diagram to clean sealing surfaces of cylinder head.   Note

The sealant beads may not be thicker, since excess sealant can otherwise get into the camshaft bearing. –  Install new cap → Item flush on cylinder head. –  Remove the camshafts with the bearing cap module and the Camshaft insert tool -T40094- from the Camshaft assembly tool -T40095-. –  Carefully insert camshafts and retaining frame into cylinder head.

–  First tighten the securing bolts hand-tight for the retaining frame in the following order: -1 ... 20-. l  The bracket support module must be supported on the entire surface on the cylinder head. –  Tighten retaining frame bolts to final torque in the sequence -1 … 24-. Tightening torque: 10 Nm. –  Remove camshaft fitting tool -T40095- and clamping tool -T40096/1-. –  Renew camshaft seal → Chapter. The remaining installation steps are carried out in reverse sequence - note the following points:   Note t  After installing cam shaft, the engine must not be started for approx. 30 minutes. The hydraulic elements should be allowed to sit in place (if not, the valves may press on the cylinder). t  After working on valve gear, carefully crank engine at least 2 revolutions by hand to ensure that no valves make contact on starting. –  Place hub back onto camshaft.

–  Tighten hub securing bolt -1- to 100 Nm. To do this, use counterhold -T10051-.

–  Slide the camshaft sprocket onto the hub.   Note The arrow on the camshaft pulley must be at almost »12 o'clock«. –  Hand tighten securing bolts -1- to camshaft sprocket so that there is no play.

–  Immobilise the hub using the retention tool -3359-. –  Install toothed belt and adjust valve timing → Chapter. –  Install exhauster pump → Chapter. –  Install cylinder head cover → Chapter. –  Install fuel filter → Chapter.