SEAT Workshop Service and Repair Manuals

Toothed belt: removing and installing - vehicle ► 05.05 with small engine support t  Removing → Anchor t  Installing → Anchor t  Tightening torques → Anchor

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	counterhold -T10100-, see equivalent → Anchor

t	Hose clamp -T10115-, see equivalent → Anchor

t	Hose clamp -T20018B-, see equivalent → Anchor

t	Hose clamp -T20102-, see equivalent → Anchor

t	Base -T20174-, see equivalent → Anchor

t	Hose clamp -T10050-, see equivalent → Anchor

t	Hose clamp -T20167-, see equivalent → Anchor

t	Turning tool -T20197-, see equivalent → Anchor

t	Socket -U 30025E-, see equivalent → Anchor

Removing Engine code letters BJB, BKC, BXE, BXF –  Pull the oil dipstick -1- out of the guide tube. –  Lift the engine cover by the sides -arrows 2- and pull it out forwards -arrow 3-. –  Replace the oil dipstick in the guide tube.

–  Lay the lines -1 ... 3- on the air pipe open. –  Remove air duct by lifting retaining clips -arrows- slightly.   Note The coolant hose -1- and fuel pipes -2- and -3- must remain connected.

Select engine identification letters BLS –  First remove the outer cover -1- and then the inner cover -2- upwards equally.

–  Remove bolt -1-. –  Remove air duct by lifting retaining clips -arrows- slightly. Continued for all vehicles   WARNING t  For those vehicles fitted with an injector pump, the temperature of the fuel and the fuel lines may reach up to 100 ºC in extreme cases. Before opening the duct connections, allow the fuel to cool otherwise there is a risk of severe burns. t  Wear eye and hand protection when performing any type of repair work on the fuel system!

–  Disconnect fuel supply -2- and fuel return pipes -1-, by pulling on the release tabs.

–  Release the fittings and pull fuel filter with hoses attached upwards out of the bracket -arrow- and secure to the side.

–  Unscrew bracket -3- for fuel filter. –  Unscrew bolts -2- for windscreen washer tank filler neck. –  Unplug connector found on coolant expansion tank -1-. –  Unbolt coolant expansion tank -1- and lay it on the cylinder head cover with hoses connected.   Note

Before removing the ribbed belt, mark its running direction with chalk or with a felt tipped pen. Running a used belt in the opposite direction could destroy it. –  To slacken the Poly-V belt, turn the tensioner in the direction of the arrow.

–  Lock Poly-V belt tensioner using the tool -T20167-. –  Remove poly V-belt.

–  Extract the bolts -arrows- and remove the Poly V-belt tensioner.

–  Remove upper notched belt guard by releasing retaining clips -arrows-.

–  Unscrew the bolts -2- and -3- on the bracket for the refrigerant tubes.

–  Unscrew the bolt -arrow- from the lower bracket for the refrigerant tubes.

–  Extract upwards, the fuel lines cover -arrow- from its allotment; to do this, disconnect the cover top and remove the tube fixations.   Note To secure the engine assembly with the support -U-30025E- this must be centred as much as possible with the symmetrical axis of the engine assembly.

–  Position bracket -U-30025E- on bolted flange for wing panels. –  Hook the carbine on the support spindles on the distribution side. –  Take up weight of engine evenly with both spindles (do not raise).

–  Unscrew bolts -1- and -2- and the joint reinforcement. –  Unscrew the bolts crossways -3 ... 6- and take out engine console –  Lift the engine / gearbox assembly using the spindle.   Note To remove the bolts for the engine support, raise or lower the engine slightly as necessary using the spindles on the engine and gearbox support -U-30025E-.

–  Unscrew the bolts -1 ... 3- from the engine mount. –  Carefully lift the refrigerant tubes to avoid damage by twisting.

–  Fit the centre noise insulation -fasteners 1 ... 3-.

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

–  Extract the engine bracket from underneath -arrows- the refrigerant tubes as shown in the illustration.

Engine code letters BJB, BKC, BXE, BXF –  Unscrew bolts -1- and -2-. –  Remove the right hand side air conduit hose; to do this, lift the retainers slightly -arrows-. Continued for all vehicles

–  Remove the vibration damper hood.   Note To loosen and to tighten the vibration damper, hold it on the centre bolt using a ring spanner. –  Unscrew the vibration damper.

–  Unscrew the lower and centre notched belt guard -arrows-.   Note

For engines before the 2004 model, the tension roller for the timing belt does not have an interior hexagon for the Allen key. In these cases use the tool -T20197- to loosen and tighten the timing belt.   WARNING The rotation of the engine must only take place on the crankshaft in the normal rotation direction of the same (clockwise).   Note The engine should revolve around the central bolt of the crankshaft.   Note

Rotate the crankshaft until the mark on the timing belt wheel of the crankshaft and the gear segment of the camshaft wheel is upwards. The mark on the rear timing belt protection should coincide with the mark on the generator wheel of the camshaft -arrows-.

–  Secure the hub using the retention tool -T20102-, the tabs -1- of the sprocket and the mark -2- of the notched belt rear protection must coincide.   Note Progressive installation of the oval wheels for the crankshaft timing belt. When fitting this type of wheel, the crankshaft should be locked using the retaining tool -T10100- or the counter hold -T10050- to determine TDC.

Distinctive characteristics of the crankshaft timing belt wheel A = Normal wheel for timing belt, lock using the counterhold -T10050-, mark the TDC in the 12 o'clock position B = Oval wheel for timing belt, lock using the counterhold -T10100-, mark the TDC in the 1 o'clock position   Note The marks on the timing belt wheel -2- and on the counter hold -T10050- or retaining tool -T10100--1- should face each other. In doing so, the journal of the counterhold -T10050- or retaining tool -T10100- should match the opening in the sealing flange.

Vehicles with round wheel for the crankshaft timing belt –  Immobilise the notched belt on the crankshaft sprocket using the crankshaft stop -T10050-.

Vehicles with an oval wheel for the crankshaft timing belt –  Secure the hub using the retention tool -T10100-, the tabs -1- of the sprocket and the mark -2- of the notched belt rear protection must coincide. –  Mark the notched belt direction of rotation with chalk or felt pen.

–  Loosen the attachment bolts -1- from the camshaft wheel with the counterhold -T20018B- until the camshaft sprocket can turn loosely in the extended holes.

–  Loosen the fixing nut of tensioning roller . –  Turn the off-centre adjustment with an Allen key -anti-clockwise- until the tension roller can be secured with the locking pin -T10115- .

–  Next turn the Allen key -in the direction of the arrow- as far as possible and hand tighten the fastening nut -1-. –  Remove the notched belt, first from the coolant pump and then from the rest of the notched belt wheels. Installing l  The camshaft is locked using the retention tool -T20102-. l  The crankshaft is locked using the counterhold -T10050- or the retention tool -T10100-. l  Tension roller locked with the counterhold -T10115- and secured on the right hand side limit with the securing nut.   Note t  Adjustment work on the timing belt should only be done when the engine is cold, given that the position of the indicator arm on the tension device will vary depending on the engine temperature. t  When turning the camshaft, the crankshaft must not be at TDC for any cylinder. Risk of piston valves / head fault.

–  Ensure that tensioning roller is seated properly in rear timing belt guard -arrow-.

–  Screw in bolts -1- partially. l  It should just be possible to turn the camshaft sprocket on the hubs without locking. –  Turn the camshaft sprocket in its longitudinal holes clockwise, as far as possible. –  Fit the notched belt to crankshaft, tensioning roller, camshaft sprocket, idler wheel and finally to sprocket for coolant pump. –  Adjust the tension of the notched belt in the following manner:

–  Unfasten nut of tensioning roller. –  Turn the off-centre adjustment with an Allen key -anti-clockwise- until the locking pin -T10115- can be removed.

–  Rotate the tension roller -clockwise-, until the indicator arm is in a centre position of the plate groove -arrow- .   Note t  Ensure that the attachment nut does not also rotate. t  Use the correct tightening torque to avoid damages to the engine when tightening the tensioner. –  Hold tensioning roller in this position and tighten securing nut to 20 Nm + 45° (1/8 turn).

–  Tighten the camshaft sprocket securing bolts -1- to 25 Nm, blocking any rotation using the counterhold -T20018B- .   WARNING The rotation of the engine must only take place on the crankshaft in the normal rotation direction of the same (clockwise). –  Remove the counterhold -T20102- and the counterhold -T10050- or the retention tool -T10100- of the crankshaft. Checking valve timing: –  Rotate the crankshaft 2 times in the normal engine direction of rotation until this is returned to just before TDC.

–  When turning the hub in the engine's normal direction of rotation, lock it using the counterhold -T20102-. –  Check if: t  The crankshaft is locked using the counterhold -T10050- or the retention tool -T10100-. t  the tension roller indicator is located in the centre position or is located max. 5 mm to the right from the base plate bracket. If the crankshaft cannot be locked using the counterhold -T10050- or the retention tool -T10100-:

–  Loosen the attachment bolts -1- from the camshaft wheel with the counterhold -T20018B- until the camshaft sprocket can turn loosely in the extended holes.

–  Turn crankshaft in the opposite direction of engine rotation until the crankshaft counterhold -T10050- or retention tool -T10100- journal is just opposite the sealing flange borehole -arrow- and insert it. –  Turn crankshaft in the opposite direction of engine rotation until the journal of the counterhold -T10050- or retention tool -T10100-engages in the borehole of the sealing flange due to the turning motion.

–  Tighten the camshaft sprocket securing bolts to 25 Nm, blocking any rotation using the counterhold -T20018B-. –  Remove the counterhold -T20102- and the counterhold -T10050- or the retention tool -T10100- from the crankshaft.   WARNING The rotation of the engine must only take place on the crankshaft in the normal rotation direction of the same (clockwise). –  Rotate the crankshaft 2 times in the normal engine direction of rotation until this is returned to TDC. –  Check the valve timing once more → Anchor. Rest of installation is carried out in the reverse sequence, observing the following: –  Fit the lower and centre notched belt protection.   Note t  Renew seals and gaskets. t  Secure all hose connections with the correct hose clips (same as original equipment) → Parts catalogue.

–  Fit the engine mount on the cylinder block and screw in the attachment bolts -1 … 3- hand tight first. –  Then tighten the bolts -1 ... 3- to 40 Nm + 1/2 turn (180°). –  Install vibration damper → Chapter. –  Adjust engine mountings → Chapter. –  Install poly V-belt → Chapter. –  Connect the air conduit guard to the turbocharger and insert the spring-type clip using the pliers -T20174-. –  Fit the supercharger air system hoses and observe the assembly instructions → Chapter.