SEAT Workshop Service and Repair Manuals

Removing and installing camshafts (with cylinder head installed)

Special tools and workshop equipment required

t	Counter-hold tool -3036-

t	Chain tensioner retainer -3366-

t	Torque wrench -V.A.G 1331- (5...50 Nm)

t	Torque wrench -V.A.G 1332- (40...200 Nm)

Not illustrated t  Sealing compound -AMV 174 004 01- t  Sealing compound -D 454 300 A2- Removing –  Remove air cleaner → Rep. Gr.24 Vehicles with engine code AJH –  Remove intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH. Vehicles with engine code AWC –  Remove intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AWC. Continuation for all vehicles –  Remove toothed belt guard upper part.

–  Set camshaft toothed belt pulley to TDC No. 1 cylinder by turning crankshaft. Marking on camshaft toothed belt pulley must align with mark on cylinder head cover. –  Remove pressure hose between combination valve and secondary air pump motor from combination valve and unclip pressure hose from brackets.   Note! Press buttons on hose couplings to do this. –  Remove toothed belt from camshaft pulley → Chapter. –  Turn crankshaft back slightly. –  Remove ignition coils with output stages → Rep. Gr.28. –  Remove cylinder head cover. –  Remove camshaft toothed belt pulley. When loosening camshaft toothed belt pulley bolt, hold with counterhold -3036-. –  Remove hall sender -G40- housing. –  Remove hall sender -G40- washer and trim.

–  Clean drive chain and camshaft chain sprocket in opposite area of both arrows on bearing caps and mark installation position with a coloured mark.   Note! t  Do not mark chain with a centre punch or any similar means! t  The distance between both arrows or the coloured marks is equal to 16 rollers on the drive chain.

–  Secure chain tensioner with chain tensioner retainer -3366-.   Note! If the chain tensioner retainer is tightened excessively, this can damage the hydraulic chain tensioner.

–  First remove 3rd and 5th bearing caps from inlet and exhaust camshafts. –  Remove double bearing cap. –  Remove both bearing caps at chain sprockets on inlet and exhaust camshafts. –  Remove chain tensioner securing bolts. –  Remove 2nd and 4th bearing caps from inlet and exhaust camshaft alternately and diagonally. –  Remove inlet and exhaust camshaft chain tensioner and chain tensioner retainer -3366-. Installing   Note! t  When camshafts are installed, cams for No. 1 cylinder must point upwards. t  When installing the bearing caps, ensure that the cap markings can be read from the inlet side of the cylinder head. –  Fit chain onto both camshafts corresponding to coloured markings.   Note!

t  When using a new drive chain, the distance between the notches -A- and -B- on the camshafts must be 16 rollers on the drive chain. t  The illustration shows the exact positions of the 1st and 16th rollers on the chain sprockets where the chain must be fitted. t  Notch -A- is offset slightly towards the inside in relation to chain roller -1-.

–  Renew rubber/metal gasket for chain tensioner and lightly coat hatched area with sealing compound -D 454 300 A2-. –  Push chain tensioner in between drive chain. –  Oil running surfaces of both camshafts. –  Insert camshafts with drive chain and chain tensioner into cylinder head. –  Tighten chain tensioner to 10 Nm (note fitted sleeves).

–  Tighten inlet and exhaust camshaft 2nd and 4th bearing caps alternately and diagonally to 10 Nm (remember dowel sleeves).

–  Install both bearing caps at inlet and exhaust camshaft chain sprockets. Check camshafts are positioned correctly -arrows- and tighten bearing cap to 10 Nm (remember dowel sleeves). –  Remove chain tensioner retainer 3366.

–  Coat double bearing cap hatched area lightly with sealing compound -AMV 174 004 01-, install and tighten to 10 Nm (note fitted sleeves). –  Install remaining bearing caps and tighten to 10 Nm (remember dowel sleeves).

–  Install camshaft sprocket (the small web faces outwards -arrow- and TDC mark is visible) and tighten securing bolt to 65 Nm (use counterhold -3036-).

–  Check position of camshafts to one another -arrows- again. –  Install washer (cone facing outwards) and tighten securing bolt to 25 Nm. –  Install Hall sender housing and tighten to 10 Nm. –  Install cylinder head cover. –  Install ignition coils and tighten to 10 Nm. Further assembly is basically the reverse of the dismantling procedure. –  Install toothed belt and adjust valve timing → Chapter.   Note! When new bucket tappets have been installed the engine must not be started for about 30 minutes. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons).