SEAT Workshop Service and Repair Manuals

Removing, installing and tensioning toothed belts; engine code AJH

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Tensioning bolt -T10092-

t	Locking pin -T40011-

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

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

Not illustrated t  Adapter -10 - 222 A /5- t  Locking fluid -D 000 600 A2- Removing –  Note safety precautions before beginning work → Chapter. –  Observe rules for cleanliness → Chapter. –  Removing poly V-belt and tensioner → Chapter. –  Unclip fuel hoses from bracket. –  Remove intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH. –  Remove air pipe between turbocharger and charge air cooler → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH. –  Remove toothed belt guard upper part. –  Mark direction of rotation of toothed belt.

–  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 belt pulley vibration damper.

–  Position support bracket -10 - 222 A- together with adapter -10 - 222 A /5-.

–  Bolt adapter -10 - 222 A /5- with body bolts -arrows-. –  Insert fastening hooks of support bracket -10 - 222 A- into lifting eye on right of cylinder head and raise engine slightly. –  Remove pendulum support → Rep. Gr.40

–  Unscrew right assembly mounting securing bolts -1-.

–  Remove bolts and nuts from engine assembly mounting -arrows- and completely remove assembly mounting. –  Raise engine as far as possible with support bracket. –  Remove engine bracket from cylinder block and lift out upwards. –  Remove centre and lower parts of toothed belt guard.

–  Screw tensioning bolt -T10092- into toothed belt tensioner. –  Align plunger using pointed pliers or thin wire before tensioning, if necessary. (Hole in plunger and hole in housing must align). –  Tension the tensioner plunger until the plunger can be locked with locking pin -T40011-. –  Remove toothed belt. –  Turn crankshaft back slightly. Installing A - Toothed belt completely removed → Anchor B - Toothed belt has only been removed from camshaft sprocket → Anchor   Note When camshaft is turned, crankshaft must not be at TDC. Danger of damage to valves and piston crowns. A - Toothed belt completely removed If toothed belt has only been removed from camshaft sprocket → Anchor. Prerequisite l  The pistons must not be positioned at TDC. Procedure

–  Line up mark on camshaft pulley with mark on cylinder head cover. –  Place toothed belt on crankshaft toothed belt pulley and coolant pump (observe direction of rotation). –  Install centre and lower toothed belt guard. (Insert securing bolts with locking fluid -D 000 600 A2-). Torque setting: 10 Nm.

–  Install vibration damper/belt pulley (can only be installed in one position). Torque setting: 25 Nm.

–  Turn crankshaft to TDC No. 1 cylinder. –  Install pendulum support → Rep. Gr.40 –  Install air pipe between turbocharger and charge air cooler → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH. –  Position toothed belt on camshaft sprocket and tension → Anchor. B - Toothed belt has only been removed from camshaft sprocket

–  Line up mark on camshaft pulley with mark on cylinder head cover. –  Turn crankshaft to TDC No. 1 cylinder. –  Position toothed belt on camshaft sprocket and tension → Anchor. Tensioning toothed belt Prerequisites l  The engine must be no more than warm to touch. l  Engine positioned at TDC No. 1 cylinder. Procedure

–  Tension toothed belt, to do this pull out locking pin -T40011- and unscrew tensioning bolt -T10092-.

–  Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference points. Continuation installing toothed belt complete –  Install toothed belt guard upper part. –  Install intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH. –  Fit engine mounting bracket to cylinder block. Torque setting: 45 Nm. –  Install engine mounting. Torque settings: → Chapter. –  Installing poly V-belt and tensioning element → Chapter. –  Install air filter → Rep. Gr.24.