SEAT Workshop Service and Repair Manuals

Toothed belt: removing and fitting - vehicles equipped with small engine support foot t  Removing → Anchor t  Fitting (adjusting the valve timing) → Anchor t  Specified torques → Anchor.   Note

For the dismounting of the Poly-V belt in vehicles with small engine support foot -1- you must dismount the engine support foot. 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 -SAT 8010-, see equivalent → Anchor.

t	Hose clamp -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	counterhold -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 cover, version 1: –  Take out the oil dipstick -1- from its guide tube. –  Lift the engine cover on one side -arrows 2- and remove it forwards -arrow 3-. –  Replace the oil dipstick in the guide tube.

Engine cover, version 2: –  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards. All vehicles (continued):   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 protection gloves. t  Wear eye protection.

–  Disconnect the fuel supply tube -2- and return tube -1-. To do this press release tabs.

–  Disconnect the fuel supply hose -2- and return hose -1- from the fuel pipes.

Fuel filter, version 1: –  Extract the fuel filter to above the support -arrow- with the hoses connected.

Fuel filter, version 2: –  Loosen the bolt by one turn -1-. –  Unscrew bolt -2- and nut -3-. –  Remove the fuel filter with the flexible hoses attached. All vehicles (continued):

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

–  Unbolt the bracket -3- for the fuel filter. –  Unscrew filler neck bolt -2- for washer fluid container. –  Unscrew coolant tank -1- and place to one side with lines connected.   Note

Before removing the ribbed belt, mark its running direction with chalk or with a felt tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause it to rupture. –  Slacken ribbed belt, turn tensioning element in -direction of arrow-.

–  Lock tensioner with retention tool -T20167-. –  Remove the ribbed belt.

–  Remove tensioning device for ribbed belt -arrows-.

–  Remove the upper protection for the notched belt; to do this, release the attachment clips -arrow-.

–  Remove the air conduit cover by releasing the side tabs -arrows-.

–  Unclip the air conduit in the lower part by releasing the tabs -arrows-. –  Remove the lower section of the air duct together with the air hose.

–  Unplug electrical connector -2- at air mass meter -G70-. –  Disconnect the breather hose -1- and the air conduit hoses -3- and -5-. –  Screw out bolt -4- and detach air cleaner housing.

–  Unscrew bolts -1- and -3-. –  Release the vacuum conduits on the rear tube of the air conduit. –  Disconnect the hose -2- from the crankshaft sump breather on the air duct. –  Remove the spring type clip using the support tool -T20174- and disconnect the air duct from the connection on the turbocharger.   Note Shown in illustration with engine removed from behind.

–  Fit the bracket -U-30025E- on the edge of the wing panels.   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. –  Engage the trigger snaps of the spindles on the lifting eyes. –  Pretension engine with both spindles equally, do not lift.

–  Unscrew bolts -1- and -2- and take joint reinforcement off. –  Unscrew bolts -3 ... 6- and remove engine console.

–  Remove centre noise insulation -mounting parts 1 ... 3-.

–  Remove the right soundproofing -Anchorage parts 1 ... 3-.

–  Unscrew bolts -1 ... 3- and remove pendulum arm support.

–  Unscrew bolts -1- and -2-.

–  Remove the air conduit hose; to do this, lift the retainers slightly -arrows-.

–  Remove the air conduit hose from the exhaust gas turbocharger; to do this, lift the retainers slightly -arrow-. –  Unscrew the bolt -arrow- from the lower bracket for the refrigerant tubes.

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

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

–  Remove bolts -1 ... 3- from the engine mount.   Note To release the engine mount supports, raise or lower the engine using the spindles of the support -U-30025E-. –  Lift the engine and gearbox assembly using the spindles.

–  Extract upwards, the fuel lines cover -arrow- from its allotment; to do this, disconnect the cover top and remove the tube fixations. –  Carefully lift the refrigerant tubes to avoid damage by twisting.

–  Extract the engine mount by the lower part of the refrigerant tubes -arrows- as shown in the illustration.   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 to the TDC of cylinder 1.   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.   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 counter hold -T10100- 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

Rotate the crankshaft until the marks on the timing belt wheel of the crankshaft and the gear segment of the camshaft wheel face upwards. The mark on the timing belt protection should coincide with the mark on the generator wheel of the camshaft -arrows-. –  Immobilise the crankshaft timing belt wheel with the counterhold -T10050- or the counterhold -T10100-. To do so, insert the counterhold in the gear teeth at the front of the timing belt wheel.   Note The marks on the timing belt wheel -2- and on the crankshaft stop -T10050- or crankshaft stop -T10100--1- should face each other. For this, the stub of the counterhold -T10050- or counterhold -T10100- should match the opening in the sealing flange.

Vehicles with round wheel for the crankshaft timing belt –  Immobilise the crankshaft notched belt wheel using the retention tool -T10050-.

Vehicles with an oval wheel for the crankshaft timing belt –  Immobilise the crankshaft timing belt wheel using the counterhold -T10100-. –  Mark the notched belt direction of rotation with chalk or felt pen.

–  Loosen the attachment bolts -arrows- from the camshaft sprocket with the counterhold -T20018B- until the camshaft sprocket can turn loosely in the extended holes. –  Immobilise the hubs using the retention tools -T20102-.

–  Loosen the securing nut -1- of the tensioning roller. –  Turn the off-centre adjustment with an allen key -in direction of the arrow- until the tension roller can be secured with the counterhold -T10115-.

–  Next turn the Allen key -in the direction of the arrow- as far as possible and hand tighten the fastening nut. –  Remove the timing belt, first from the coolant pump and then from the rest of the timing belt wheels. Fitting (adjusting the valve timing)   Note Adjustment work on the timing belt should only be done with the engine cold, given that the position of the tension element will vary depending on the temperature. l  Hubs immobilised using the retention tools -T20102-. l  The crankshaft is locked using the counterhold -T10050- or the counterhold -T10100-. l  Tension roller immobilised with the retention tool -T10115- fitted in the right full position.

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

–  Lightly screw in the bolts -arrows-. –  Rotate the camshaft wheels on their holes in a clockwise direction to the limit. –  Fit the notched belt on the crankshaft, the tension roller, the camshaft wheels, the idle wheel and, lastly, onto the notched belt wheel of the coolant pump. –  Adjust the tension of the notched belt in the following manner:

–  Loosen the securing nut -1- of the tensioning roller. –  Rotate the tension roller cam with an Allen wrench until it is possible to remove without force the retention tool -T10115-. –  Rotate the off-centre of the tension roller using an Allen key -clockwise - until the indicator -2- is centred in front of the bed plate space.   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 the tension roller in this position and tighten the tension roller to 20 Nm + 45° (1/8 turn)   Note

When the attachment nuts are tightened, the pointer turns -arrow- from the opening of the baseplate to maximum 5 mm to the right. This position should not be corrected, given that the belt sits into place with time.

–  Fit the retention tool -T20018B- as shown in the illustration, and maintain the camshaft wheels under tension pressing in the -direction of the arrow-. –  Tighten the bolts -arrows- of the camshaft wheels to 25 Nm. –  Remove the counterhold -T20102- and the counterhold -T10050- or the counterhold -T10100- .

Check the valve timing:   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 just before cylinder 1 TDC. –  When turning the hub -A- in the engine direction of rotation, lock it using the retention tool -T20102-. –  Check: t  the hub may be immobilised -B- with the retention tool -T20102-; t  The crankshaft is locked using the counterhold -T10050- or the counterhold -T10100-. t  the tension roller indicator is located in the centre position or deviates 5 mm to the right from the base plate bracket. If the hub cannot be locked -B-:

–  Extract the bolts -1- from the camshaft sprocket. -A- l  The hub -A- should be locked using the counterhold -T20102-

–  Turn the crankshaft until the camshaft sprocket hub is locked -B- using the counterhold -T20102-. –  Extract the bolts -2- from the camshaft sprocket -B-

–  Turn crankshaft in the opposite direction of engine rotation until the crankshaft counterhold -T10050- or counterhold -T10100- stub is just opposite the sealing flange hole -arrow- and insert it. –  Turn the crankshaft in the direction of the engine rotation until the crankshaft counterhold stub engages in the sealing flange with a rotating movement.

–  Fit the retention tool -T20018B- as shown in the illustration, and maintain the camshaft wheels under tension pressing in the -direction of the arrow-. –  Tighten the fuel inlet camshaft wheel attachment bolts -arrows- to 25 Nm. –  Remove the counterhold -T20102- and the counterhold -T10050- or the counterhold -T10100- of 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. 1. –  Check the valve timing once more → Anchor. Assembling Rest of installation is carried out in the reverse sequence, observing the following: –  Fit the lower and centre notched belt protection.   Note t  Before assembling the support unit, all the engine mount bolts should be tightened to the prescribed torque. 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 new attachment bolts -1 … 3- first by hand. –  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 duct from the connection on the turbocharger and fit the spring type clip using the support tool -T20174-. –  Fit the charge air system lines, follow the instructions during this → Chapter. Specified torques .

Component		Nm
Notched belt tensioning roller to cylinder head		20 + 45° → Note
Camshaft pinion to bin		25
Bottom section of notched belt guard to cylinder block		10 → Note
Centre section of notched belt guard to cylinder block		10 → Note
Vibration damper to the crankshaft wheel		10 + 90° → Note → Note
Engine mount to the engine block		40 Nm +1/2 turn further (180º)
Engine console to body		50
Engine mount to engine console		40 + 90° → Note → Note
Connection to engine console/body		20 + 90° → Note → Note
Pendulum support to subframe		100 + 90° → Note → Note
Front supercharger air tube to the engine block		22

1)  45° is an eighth of a turn 2)  Fit with locking fluid; locking fluid → Parts catalogue 3)  Replace bolts 4)  90º is equivalent to a quarter turn