SEAT Workshop Service and Repair Manuals

Toothed belt: Removing and installing (vehicles with two-piece toothed belt guard) t  Removing → Anchor t  Installing → Anchor   Note Vehicles from 01/2006 onwards are fitted with a new type of toothed belt cover. Differentiation: the top section of the toothed belt guard does not have a cover → Item and the toothed belt guard is divided in the area of the engine bracket. Toothed belt: Removing and installing (vehicles without two-piece toothed belt guard → Chapter) Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required

t  Socket -U30025E-, see equivalent → Anchor

t  Turning tool -T10020-, see equivalent → Anchor t  Torque wrench -VAG 1331-, see equivalent → Anchor. t  Torque wrench -VAG 1332-, see equivalent → Anchor. Removing –  Remove the engine cover / air filter → Chapter. Vehicles with engine codes BWJ, CDLD, CDLA –  Remove the air circulation duct on the turbo-charger → Item

Continued for all vehicles For safety reasons, fuse SC 27 on lower left of the dash panel must be removed from fuse holder before fuel system is opened because fuel pump can be activated by the door contact switch in driver door.   WARNING Fuel supply line is pressurised. Wear safety goggles and appropriate clothing to avoid injury and contact with skin. Before loosening hose connections, wrap a cloth around the connection. Then eliminate the pressure by carefully separating the pipe.

–  Mark the fuel pipe -1- and the pipe to the activated carbon tank -2-. –  Disconnect fuel line -1-. –  Disconnect ACF line -2-. –  Disconnect ACF line going to tank -3-. –  Lift out ACF in -direction of arrow-.

–  Detach the coolant hose at the bracket -1-. –  Remove bracket for activated charcoal filter -arrows-.

–  Unbolt filler neck for windscreen washer reservoir -1-. –  Remove retaining clip; to do so, unscrew bolts -2 and 3-.   WARNING Steam may be released when opening the expansion tank. Wear safety goggles and appropriate clothing to avoid injury to eyes and burns. Cover the cap with a cloth and open carefully. –  In order to relieve the pressure, the coolant expansion tank must now be opened and closed again.

–  Loosen the clamp -arrow- and release the coolant hose. Clean up any spilt coolant with a cloth.

–  Disconnect connector -1-. Release the coolant reservoir, and leave to one side. –  Remove poly V-belt → Chapter.

–  Remove tension device for Poly-V belt -arrows-.

–  Detach coolant pipe -arrows-.

–  Remove bolts -arrows- and detach toothed belt cover.

–  Position the support -U30025E- on the edges of the wings. –  Place the spindle hook in the right-hand side suspension eye and slightly pre-tension.   Caution Take care not to damage the edges of the wings.

–  Unscrew the securing bolts -arrows- and remove the engine soundproofing..

–  Fit the right noise insulation -fastening parts 1 ... 3-.

–  Unscrew bolts -arrows- and remove charge air pipe together with hoses.

–  Turn the crankshaft until the camshaft sprocket reaches the TDC position. The mark on the camshaft sprocket must be aligned with the arrow on the upper notched belt guard.

–  Remove vibration damper/belt pulley.

–  Unscrew the lower bolts -arrows- of the timing belt protector.

–  Loosen the lower bolt -3-.   Note The following operations are necessary in order to raise the engine sufficiently.

–  Remove the primary exhaust pipe with catalytic converter -arrows-.

–  Unscrew bolts -2- and -3- of the pendulum arm support.   Note The air-conditioner need not be opened.

–  Remove the air-conditioning hose clamps from the bodywork -arrows-.

–  Remove the bolts securing the support assembly/engine support -arrows-, and disassembly the whole support assembly.   Caution When raising the engine with the support -U30025E-, prevent the components/hoses from being damage, excessively stretched or pulled off.

–  Raise engine using the support -U30025E- until the two upper bolts -1 and 2- of the engine mounting can be loosened and removed. –  Raise the engine further until the engine mounting can be removed from the top. –  Lower the engine up to assembly position.

–  Mark the TDC -arrow-.

–  Loosen the upper bolts of the notched belt guard -arrows-, and remove the notched belt guard towards the lower part of the engine. –  Remove the engine supports upwards. –  Mark the toothed belt D.O.R. –  Release the tension roller and remove the notched belt. –  Turn crankshaft back slightly. –  Remove the notched belt . Installing   Note t  When turning camshaft, crankshaft should not be at TDC. Danger of damage to the valves/piston base. t  Engine at tepid temperature at most.

–  Set crankshaft and camshaft to cylinder 1 TDC -arrows-. –  Place notched belt on crankshaft sprocket (observe direction of rotation).

–  Fit the notched belt as follows: tensioning roller, camshaft sprocket, coolant pump and finally idle roller -arrow- .   Note

Ensure the correct seating of the tension roller in the cylinder head.

–  Tense the notched belt. To do so, turn the Allen key in the eccentric towards the right (direction of the arrow), until the notch is above the tab (notched belt too tense). –  Slacken timing belt again. –  Now tense the timing belt until the notch is aligned with the tab. –  Tighten the securing nut to 25 Nm. –  Turn the crankshaft a further two turns in the engine direction of rotation, and place it in TDC again. It is important that the last 45° (1/8 turn) is turned without stopping. –  Check again if timing belt is tense. Specification: Indicator and notch are aligned.

–  Check valve timings again. If the marks do not coincide: –  Readjust the valve timings. If the marks coincide:

–  Place the engine bracket in the assembly position. –  Fit the vibration damper using new bolts.

–  Check valve timing again: The marks must coincide -arrows-.

–  Tighten the upper bolts -arrows- of the notched belt protector. –  Fit the block bracket to the engine and tighten the bolts manually.   Note

Take into account the different lengths of the bolts. Note that bolt -3- is approximately 25 mm shorter than bolts -1 and 2-. –  Lower the engine with the support -U30025E- until the bottom bolt can be tightened -3-. –  Tighten all bolts to 45 Nm. –  Lower the engine up to assembly position. –  Fit the engine assembly support completely. Tightening torques → Chapter

–  Screw in the bolts of the engine support assembly and the engine support -arrows- by hand. Bring the surfaces into contact using the suspension device -U30025E-. –  Align engine mountings as follows:

t  There must be a distance -a- of at least 10 mm between engine support and longitudinal member (right side). t  The side surface of the engine support -2- should be located parallel to the support arm -1-. –  Tighten the bolts of the engine support assembly and the engine support. Tightening torque: 60 Nm +1/4 turn further (90°). –  Remove the support -U30025E-. –  Install poly V-belt → Chapter. –  Connect the fuel hoses to the couplings. Ensure that the female couplings are firmly connected. –  Install coolant expansion tank. –  Fit the noise insulation tray → Bodywork, exterior fitting work; Rep. gr.50. –  Replace fuse SC 27 in the fuse holder. –  Fit the engine cover / air filter → Chapter.