SEAT Workshop Service and Repair Manuals

Distribution timing: adjustment

Special tools and workshop equipment required

t	Dial gauge -VAS 6079-

t	Extractor -T10094 A-

t	Dial gauge adapter -T10170- or dial gauge adapter -T10170 A-

t	Camshaft clamp -T10171 A-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t	Torque wrench -V.A.G 1601-

t	Counterhold tool -3415-

t	Securing bolt -T10340-

t	Torque wrench -V.A.G 1331-

t  Spark plug socket and extension -3122 B-

Operation process –  Unplug connector -1-. –  Remove bolts -arrows-. l  Gas hoses remain connected to gas rail. –  Release the wiring from the fixing of the carrier cover and from the gas hoses. –  Place the gas distribution rail „Gas rail“ aside without removing the cables and hoses.

–  Remove bolts -arrows- and lift the carrier cover upwards and away. –  Remove distribution chain → Chapter.

–  To turn crankshaft, reinstall bearing bush, crankshaft pulley -2- and crankshaft bolt -3- and securely tighten crankshaft bolt (use counterhold 3415). –  Remove the cylinder 1 spark plug. To do so, use the extractor -T10094 A- and the spark plug spanner 3122 B.

–  Screw dial gauge adapter -T10170- into spark plug hole to stop. –  Insert the dial gauge -VAS 6079- with extension -T10170/1- as far as the stop and secure using locking nut -arrow-. –  Turn crankshaft in engine direction of rotation to TDC for No. 1 cylinder: Note the position of the small dial gauge. –  Then, turn crankshaft back 45° in direction opposite to engine's direction of rotation.

–  Push the tensioning rail -1- in the direction of the arrow and lock the piston with the bolt -T40011-.

–  Mark direction of rotation of timing chain -3- using coloured felt tip marker pen. –  Remove bolts -2- and -4- and take out the variator -1- and -5- together with the timing chain -3-. Use counterhold tool -T10172-. –  Re-fit chain sprockets -1- and -5-. –  Replace bolts -2- and -4- and tighten to 50 Nm (using counterhold tool -T10172-). –  Remove sealing cover from camshaft housing → Chapter.

–  Turn inlet and exhaust camshafts until camshaft clamp -T10171 A- can be inserted into holes in camshaft to stop. Locking pins -arrows 1- must engage in holes -arrows 2-. Inscription „TOP“-arrow 3- must be readable from above.   Note Camshafts must not be pushed axially whilst turning.

–  Install a M6 bolt -arrow- hand-tight (do not tighten) to secure camshaft clamp -T10171 A-. –  Loosen the screws of the camshaft chain sprockets. The counterhold -T10172- must be used for this in all cases.   Note The camshaft clamp -T10171 A- must not be used as a counterhold tool. –  Remove one camshaft sprocket. –  Place the timing chain on the camshaft sprockets, taking into account the running direction, and then re-fit the removed camshaft sprocket. –  Tighten camshaft bolts until camshaft sprockets can still just be turned on camshafts. –  Tension timing chain by removing locking pin -T40011-.

–  Turn crankshaft in engine direction of rotation to TDC for No. 1 cylinder: Permissible deviation from TDC for cylinder 1:  ±  0.01 mm.   Note When the crankshaft rotates more than 0.01 mm beyond the TDC, the crankshaft must be rotated by approx. 45° against the direction of the engine again. Then turn crankshaft in direction of engine rotation to TDC No. 1 cylinder.

–  Undo the screw plug -arrow- in the crankcase. –  Screw threaded locking pin -T10340- into crankcase as far as it will go. –  Tighten threaded locking pin -T10340- to 30 Nm.

Locking pin -T10340- locks crankshaft in direction of engine rotation.

–  Hold camshaft sprockets -1- and -5- in this position with counterhold -T10172- then tighten bolts -2- and bolt -4- to 50 Nm.   Note Do not turn crankshaft when tighten the camshaft bolts. The control chain -3- must be tense on both sides. –  Remove camshaft clamp -T10171 A-.

–  Unscrew threaded locking pin -T10340- from crankcase. –  Turn crankshaft by 2 rotations in engine direction of rotation to TDC for No. 1 cylinder: Permissible deviation from TDC for cylinder 1:  ±  0.01 mm.

–  Insert camshaft clamp -T10171 A- as far as stop in camshaft openings. If the camshaft clamp -T10171 A- cannot be inserted: –  adjust again. If the camshaft clamp -T10171 A- can be inserted:

–  Screw threaded locking pin -T10340- into crankcase as far as it will go. –  Tighten threaded locking pin -T10340- to 30 Nm.

–  Remove camshaft retainer -T10171 A-. Hold camshaft wheels with counterhold -T10172- and tighten bolts -2- and -4- a 1/4 turn (90°) further with a rigid wrench.   Note Camshaft sprockets must not move on camshaft whilst tightening. –  Turn crankshaft by another 2 rotations in engine direction of rotation to TDC for No. 1 cylinder. Permissible deviation from TDC for cylinder 1:  ±  0.01 mm.

–  Insert camshaft clamp -T10171 A- as far as stop in camshaft openings. If the camshaft clamp -T10171 A- cannot be inserted: –  adjust again. Further assembly is basically the reverse of the dismantling sequence. Note the following:   Note The locking pin -T10340- remains in the crankcase until the crankshaft pulley is installed. t  Install valve timing housing → Chapter. t  Installing poly V-belt → Chapter t  Renew seals for camshaft sealing caps and lubricate with oil before installing.

–  Install the carrier cover and tighten the screws -arrows- to a tightening torque of 8.5 Nm. –  Mount the cables and gas hoses on to the fixing points of the carrier cover.

–  Install the fuel rail „Gas rail“ and tighten the screws -arrows- to a tightening torque of 4 ± 0.4 Nm. –  Insert the connector -1-.