SEAT Workshop Service and Repair Manuals

Distribution timing: adjustment

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Engine support bracket, basic set -T40091-

t	Assembly tool -T10476-

t	Locating bolt -T10340-

t	Camshaft clamp -T10477-

t	Torque wrench -V.A.G 1332-

t	Adapter -10-222 A/31-2- (not illustrated)

t	Support -10-222 A/31-3- (not illustrated)

t	Adapter -10-222 A/31-5- (not illustrated)

t	Square tube -T40091/1- (not illustrated)

t	Connector -T40091/3- (not illustrated)

Operation process –  Remove air cleaner housing → Chapter.

–  Unlock and disconnect fuel supply line -1- and breather line -2-. → Fuel supply system - Petrol engines; Rep. gr.20. –  Open line guide -3- and detach hoses. –  Seal lines so that fuel system is not contaminated by dirt. –  Detach clamps -arrows-.

–  Unscrew securing bolt -1- and remove cover -2-. –  Undo and remove bolts -arrows-.

–  Unclip duct from the guard. –  Remove cover -1- and cover -2-.

–  Unscrew plug -arrow- from crankcase. –  Lower lifting platform completely.   Note t  The lifting platform must be lowered completely in order to allow for screwing the locking pin -T10340- into the crankcase. t  When the vehicle is raised, the hole is hidden behind the drive shaft.

–  Screw locking pin -T10340- into crankcase from above as far as it will go.   Caution If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position! In this case, proceed as follows. –  Unscrew locking pin. –  Turn crankshaft 90° in direction of rotation of engine. –  Screw locking pin -T10340- into crankcase as far as it will go. –  Tighten locking pin -T10340- to 30 Nm. –  Turn crankshaft in direction of rotation of engine as far as the stop. Locking pin -T10340- locks crankshaft in direction of engine rotation. –  Removing poly V-belt → Chapter –  Remove windscreen wiper arms → Electrical system; Rep. gr.92. –  Remove plenum chamber cover → General body repairs, exterior; Rep. gr.50.

–  Fit adapter -10-222A/31-2- onto suspension struts. –  Angle pieces of adapters -arrow- point towards engine compartment.

–  Position support -10-222A/31-5- above bonnet catch. –  Correct position is between 2 lugs -arrow-.

–  Fit support bracket -10 - 222 A- and engine support basic set -T40091- with adapters as shown. –  Support engine on right eye and slightly release load from assembly mounting by turning spindle. –  Disconnect earth wire -1-.

Unscrew securing bolts -arrows- and remove assembly mounting on engine side.

–  Unscrew securing bolts -1- and swivel alternator in -direction of arrow-. –  Lift motor up sufficiently by turning spindle in order to allow for unscrewing securing bolt of engine mounting.

–  Unscrew securing bolts -2- of engine mounting and 3 bolts -1- of lower toothed belt guard. –  Lift out engine mounting upwards.   Caution When loosening and tightening the securing bolts, the camshaft sprockets must in any case be secured with the counterhold -T10172-. The camshaft clamp -T10477- may not be subjected to load when tightening the camshaft sprockets in order to avoid damage to the tool or to the camshafts.

–  Secure camshaft adjuster with counterhold -T10172- and unscrew plug -1-.   Note When adjusting the valve timing, both camshaft sprockets must be loose. –  Secure camshaft adjuster and camshaft sprocket with counterhold -T10172-.

–  Loosen securing bolts -1- and -2-. –  Loosen securing bolt -3- of belt tensioner and release tension of belt tensioner by turning the eccentric -4- (hexagon socket insert) in -direction of arrow-. –  Push toothed belt from camshaft sprockets.

–  Renew securing bolts -1- and -2- and tighten them hand-tight. –  Rotate camshafts via securing bolts -1- and -2- into positions described below.

–  Grooves -1- of inlet camshaft -3- are positioned right above horizontal camshaft centre line -2-. –  Grooves -1- of exhaust camshaft are positioned right above horizontal camshaft centre line -2-.

–  Recesses of gear -3- in area of grooves are slightly more oriented above horizontal camshaft centre line.   Caution The camshaft clamp -T10477- must slide into position easily. The camshaft clamp must not be positioned using any kind of hammer.

–  Insert camshaft clamp -T10477- to stop into camshafts and tighten bolt -arrow- by hand. –  Loosen securing bolts of camshaft sprockets until sprockets can easily be rotated by hand.

Align marked gap -1- of camshaft adjuster -3- with lug -2- of camshaft housing.

Align marked tooth -1- of exhaust camshaft sprocket -3- with lug -2- of camshaft housing.

–  Markings -1- and -2- on camshaft sprockets are aligned as shown. Groove -3- for assembly tool -T10476- is located on exhaust camshaft sprocket. –  Insert assembly tool -T10476- between camshaft sprockets.

–  Arrows -1- on assembly tool are aligned with marks -2- on camshaft sprockets.   Note When the assembly tool -T10476- is inserted, the marks -2- on the camshaft sprockets are slightly offset.

–  Dowel pin -1- of assembly tool -T10476- must engage in groove -2- of exhaust camshaft sprocket. –  Hand-tighten belt tensioner -3- on cylinder head.

–  Hook -1- must be positioned in recess -2-. –  Orientation of eccentric -4- of belt tensioner must be as shown.   Note t  In this position the belt tensioner is completely free of tension. t  When installing the toothed belt, ensure that the assembly tool -T10476- is correctly positioned between the camshaft sprockets. –  Toothed belt must make full contact with crankshaft sprocket. –  Check if the crankshaft is in cylinder 1 TDC position. The crankshaft must make contact with the locking pin -T10340- in direction of engine rotation.

–  Fit toothed belt -1- onto belt tensioner -5- and camshaft sprocket -2-. –  Then fit toothed belt on camshaft adjuster -3- and on idler roller -4-. –  Remove assembly tool -T10476- from camshaft sprockets. –  First turn the eccentric -1- in the -direction of the arrow- until the adjustment pointer -2- is positioned about 10 mm to the right of the setting window -3-.

–  Then rotate eccentric of belt tensioner back using hexagon socket insert at position -1- until adjustment pointer -2- is exactly centred in adjustment window -3-. –  Hold eccentric in that position using hexagon socket insert at position -1-. –  Tighten securing bolt -4- to 25 Nm.   Note t  When the engine has been rotated by hand or by engine operation, the position of the adjustment pointer -2- might be slightly offset from the adjustment window -3-. t  However, this has no relevant influence on the valve timing. –  Secure camshaft adjuster and exhaust camshaft sprocket with counterhold -T10172-.

–  Tighten securing bolts -1- and -2- to 50 Nm.   Note The securing bolts will be tightened with a further tightening angle of 90° at the end of the work sequence after the valve timing has been checked.

–  Remove locking pin -T10340- from above with lifting platform lowered.

–  Unscrew bolt -arrow- and remove camshaft clamp -T10477-. –  Turn crankshaft 2 turns in direction of rotation of engine. –  Screw locking pin -T10340- into crankcase as far as it will go.   Caution The camshaft clamp -T10477- must slide into position easily. The camshaft clamp must not be positioned using any kind of hammer. –  Insert camshaft clamp -T10477- to stop into camshafts and tighten bolt by hand. The valve timing is OK, if the camshaft clamp -T10477- can be pushed into the camshafts. If control times are not OK –  Repeat adjustment of valve timing. –  Remove camshaft clamp -T10477-. –  Secure camshaft adjuster and exhaust camshaft sprocket with counterhold -T10172-.

–  Turn securing bolts -1- and -2- 90° further. –  Renew O-ring of plug if damaged.

–  Tighten camshaft adjuster plug -1- to 20 Nm.

–  Remove locking pin -T10340- from above with lifting platform lowered.   Caution After completing work, it is essential to ensure that the locking pin -T10340- and the camshaft clamp -T10477- have been removed. Tightening torques Tightening torque of the cylinder block oil filler neck: 30 Nm Assembly overview - cylinder block (pulley end) → Chapter. Assembly overview - assembly mountings → Chapter Further assembly is basically the reverse of the dismantling sequence.