SEAT Workshop Service and Repair Manuals

Fitting   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. The axial bearings in the retaining frame will otherwise be damaged beyond repair and the cylinder head will have to be renewed. –  Remove sealant residues on cylinder head and retaining frame, e.g. using a rotating plastic brush.   Caution Make sure that no sealant residue gets into the cylinder head or the bearings. –  Clean sealing surfaces; they must be free of oil and grease. –  Oil the camshaft running surfaces. If not already done, set up camshaft fitting tool -T40094- as follows:

–  Detach the brackets -T40094/3-, -T40094/4- and -T40094/5- from the base plate. Threaded connection is accessible from below.   Note If the supports of the camshaft fitting tool -T40094- are not marked at present, mark the removed supports, e.g. with number stamps, so they can be fitted in the original positions later.

–  Instead of the integrated brackets, attach the brackets -T40094/9- and -T40094/10- to the exterior freed holes. –  Place support -T40094/2- at position labelled „A“ and support -T40094/1- at position labelled „F“. –  First attach the inlet camshaft as shown. Ensure that indentation -arrow- for cylinder head bolt faces »outwards«.

–  Set 0.50 mm feeler gauge in place and push support -T40094/8- into groove on inlet camshaft.

–  Now attach the exhaust camshaft and lock above its groove -Arrow- with the -Cover T40094/11-. –  Fit clamping tool -T40096/1- onto exhaust camshaft gears.   Caution Ensure that the clamping jaw marked with an arrow is seated on the wider gear.

–  Secure the Tensioner -T40096/1- with the knurled wheel till the tooth flanks are aligned. If required, counterhold with an open-ended wrench SW 13. –  Push the exhaust camshaft to the inlet camshaft till the teeth interlock. –  Position retaining frame on camshafts. l  All camshaft bearings must be seated on the camshafts.

–  Set clamping tool -T40095- in place as illustrated in order to hold camshafts in position in retaining frame. –  Remove cover -T40094/11-. –  Pull support -T40094/8- out of inlet camshaft groove.

–  Cut off pipe connection at the front marking (nozzle Ø: approx. 2 mm). –  Apply beads of sealant (approx. 2 ... 3 mm width) -arrows- onto clean sealing surfaces of cylinder head as illustrated.   Caution Risk of soiling camshaft bearings due to surplus sealant and risk of sealing oil supply bores. t  Do not apply sealant beads thicker than specified. t  In area of oil supply bores -arrow- for retaining frame, make sure that these are not sealed due to surplus sealant.

Sealant bead for retaining frame –  Take camshafts out of camshaft fitting tool -T40094- together with retaining frame and clamping tool -T40095-. –  Carefully position camshafts and retaining frame in cylinder head.

–  First tighten securing bolts of retaining frame hand-tight in sequence -1 … 24-. l  The retaining frame of the bearing cover 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 the Camshaft insert tool -T40095- and the camshaft insert tool -T40096/1-. –  Renew camshaft oil seal → Chapter. –  Using a suitable drift, knock new sealing cap (core plug) → Item in cylinder head until flush. The remaining installation steps are carried out in reverse sequence - note the following points:   Caution Avoid damage to valves and piston crowns after working on valve gear. t  Because hydraulic compensation elements have to settle, engine must not be started for approx. 30 minutes after installing camshafts. t  Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. –  Fit hub onto camshaft.

–  Tighten hub securing bolt -1- to 100 Nm. Use counter-hold tool -T10051- to do this. –

–  Push camshaft sprocket onto hub.   Note The toothed segment -arrow- of the camshaft belt pulley must be on top. –  Hand tighten securing bolts -1- to camshaft sprocket so that there is no play. –  Lock hub using locking pin -3359-. –  Install toothed belt and adjust the valve timing → Chapter. –  Install exhauster pump → Chapter. –  Install the cylinder head cover → Chapter. –  Install the fuel filter → Chapter and the auxiliary fuel pump -V393- → Chapter