SEAT Workshop Service and Repair Manuals

Notes:

• ◆ If during repair work, metal shavings or larger quantities of small metal particles are found in the engine oil - caused, for example, by partial seizure of the crankshaft and conrod bearings - then, apart from thoroughly cleaning out the oil passages, it is necessary to renew the oil cooler.
• ◆ Defective injectors can cause violent knocking noises in the engine which sound like defective bearings. When this occurs, run engine at idling speed and slacken off injector pipe unions one after the other. If knocking stops when a union is loosened, this indicates that the injector concerned is defective.

Servicing injectors.

=> Repair group 23; Diesel direct injection system; Servicing injectors

I    

II    

III    

Part I

• 55 Nm
• 20 Nm
• Engine support bracket
• Toothed belt guard - upper part
• Toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing, installing and tensioning
  
• Eccentric
• Tensioning roller
• ◆ Checking => Page 13-25
• ◆ Tensioning toothed belts
  => Page 13-17

• 45 Nm
• Camshaft sprocket
• ◆ Drive off camshaft taper using hammer and drift through toothed belt guard openings
• 25 Nm
• Idler wheel
• 10 Nm
• Rear toothed belt guard
• Retaining clip
• Injection pump sprocket
• Intermediate shaft sprocket
• Crankshaft toothed belt sprocket

• 90 Nm + 1/4 turn (90 °) further
• ◆ Counter-hold with 3099 to loosen and tighten
• ◆ Renew
• ◆ Oil threads and shoulder
• ◆ The quarter turn further can be done in several stages.
• Injection pump
• ◆ Removing and installing:

=> Repair group 23; Diesel direct injection system; Removing and installing injection pump

• Woodruff key
• ◆ Check for tight fit
• Bracket
• Console
• Toothed belt guard - lower part

• Pulley
• ◆ For coolant pump
• ◆ Version for ribbed belt
• Ribbed belt
• ◆ Mark direction of rotation before removing
• ◆ Removing and installing
  => Page 13-16
• Belt pulley/vibration damper
• ◆ Can only be installed in one position. Holes are off-set
• V-belt
• ◆ Adjusting V-belt tension:

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir and hydraulic pipes

• Belt pulley
• ◆ For coolant pump
• ◆ V-belt version

• Belt pulley
• Dust cap
• Tensioning lever

Part II

• Cylinder head cover
• Cap
• ◆ Renew seal if damaged
• Upper sealing washer
• Dished washer
• 10 Nm
• Cap
• To intake hose
• Retaining clip
• Pressure regulating valve
• ◆ For crankcase breather
• Gasket
• ◆ Renew if damaged

• Crankcase breather
• Cylinder head cover gasket
• ◆ Renew if damaged
• ◆ Insert projections into holes on cylinder head
• Cylinder head bolt
• ◆ Note sequence when loosening and tightening
  => Page 15-7, removing and installing cylinder head
• Lower sealing cone
• Injector pipes
• ◆ Tighten to 25 Nm
• ◆ Remove with 3035
• ◆ Always remove pipework complete
• ◆ Do not alter shape

• Cylinder head
• ◆ Removing and installing
  => Page 15-1
• ◆ If replaced renew the complete
  coolant
• Cylinder head gasket
• ◆ Renew
• ◆ Note marking
  
• ◆ If replaced renew the complete
  coolant
• 20 Nm
• Lifting eye

Part III

• Cylinder block
• ◆ Removing and installing sealing flange and flywheel/drive plate => Page 13-27
• ◆ Removing and installing crankshaft => Page 13-35
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-39
• O-ring
• ◆ Renew if damaged
• Turn 20 Nm + 1/4 turn (90 °)
  further
• ◆ Renew
• Vacuum pump
• Clamp
• 20 Nm

• Crankcase breather
• Gasket
• ◆ Renew
• Banjo bolt, 25 Nm
• To turbocharger
• Seal
• ◆ Renew
• 25 Nm
• Oil filter bracket
• Oil cooler
• ◆ Coat contact area to flange, outside the seal, with AMV 188 100 02
• ◆ Ensure clearance to adjacent components
• ◆ See note
  => Page 13-1

• Oil filter
• ◆ Loosen with strap wrench
• ◆ Tighten by hand
• ◆ Note instructions on filter when installing
• 10 Nm
• Engine speed sender (G28)
• ◆ Checking:

=> Repair group 01; Self-diagnosis; Interrogating fault memory

• Clamp
• Spreader rivet
• Sump cover
• Tensioning element
• Sealing ring
• ◆ Renew if damaged

• 30 Nm
• Bracket
• Tensioning lever
• Hammer head bolt
• Coolant pump
• ◆ Dismantling and assembling => Page 19-8
• Sump
• ◆ Clean sealing surface before installing
• 20 Nm
• ◆ Remove and install both rear bolts gearbox end with jointed spanner 3185
• Bracket
• ◆ For vane pump

• Gasket
• ◆ Renew
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
• Woodruff key
• ◆ Check for tight fit