SEAT Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Lever 3299
• ◆ Setting bar 2065 A
• ◆ Pin 2064
• ◆ Pin wrench Matra V159
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)

With engine removed:

• ◆ TDC setting device 2068 A

Removing

• ‒ Remove ribbed belt .
• ‒ Remove ribbed belt tensioning roller.
• ‒ → Unscrew counter weight securing nuts -2- and remove counter weight.

• ‒ → Remove securing bolts -1- and -2- and remove engine mounting -3-.
• ‒ Remove upper toothed belt guard and cylinder head cover.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow-.

• ‒ → Turn crankshaft to TDC No. 1 cylinder (vehicles with automatic gearbox):
  Turn crankshaft until the TDC marking on the drive plate and the sight hole reference edge align -arrows-.

Engine removed:

Vehicles with manual gearbox

• ‒ → Install adjustment device 2068 A as shown.
• ‒ Set adjustment device to 96 mm -arrow A-. The left-hand notch of the vernier scale is reference point.
• ‒ Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-.

Vehicles with automatic gearbox

• ‒ → Install adjustment device 2068 A as shown.
• ‒ Set adjustment device to 75 mm -arrow A-. The left-hand notch of the vernier scale is reference point.
• ‒ Turn crankshaft until the TDC marking on drive plate aligns with point of setting device -arrow B-.

Continuation for all vehicles

• ‒ → Lock camshaft with setting bar.
• ‒ Centralize setting bar as follows:
  Turn camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge establish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd feeler gauge, of same thickness, at the other end between setting bar and cylinder head.

• ‒ → Lock injection pump sprocket with pin.
• ‒ Loosen tensioner.
• ‒ Remove vibration damper and belt pulley.
• ‒ Remove lower toothed belt guard.
• ‒ Mark D.O.R. of toothed belt.
• ‒ Remove idler roller.
• ‒ Take off toothed belt.

Installing

• ‒ Check whether TDC mark on flywheel and reference mark are aligned.

Note:

Never use setting bar as a counter hold when loosening and tightening the camshaft sprocket, use retainer 3036.

• ‒ → Loosen camshaft sprocket securing bolt 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through rear toothed belt guard opening).
• ‒ Fit toothed belts (note D.O.R.) on crankshaft toothed belt sprocket, intermediate wheel, injection pump sprocket and tensioning roller.

• ‒ Fit camshaft sprocket together with toothed belt and locate with securing bolt (camshaft sprocket can still turn).
• ‒ Install idler roller.
      Tightening torque: 25 Nm
• ‒ → Turn tensioning roller with pin wrench (e.g. Matra V159) to right until notch aligns with raised portion (arrows).

Note:

If the eccentric has been turned too far the tensioning roller must be relieved completely and retensioned. The eccentric must never be turned back when it has been turned too far.

• ‒ Tighten lock nut on tensioning roller.
      Tightening torque: 20 Nm
• ‒ Check again whether TDC mark on flywheel and reference mark are aligned.
• ‒ Tighten camshaft sprocket securing bolt to
  45 Nm.
• ‒ Remove setting bar.
• ‒ Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
• ‒ Check if
      the TDC marking on the flywheel
      the setting bar in the camshaft
      the tensioning roller adjustment (notch/raised mark)
  aligns.
• ‒ If notch and raised mark do not align, tension the tensioning roller. To do this, hold tensioning roller with pin wrench Matra V159, loosen securing nut, turn eccentric clockwise further until notch and raised mark align opposite one another and tighten securing nut to 20 Nm.
• ‒ Install toothed belt guard, vibration damper, belt pulley, and cylinder head cover.

• ‒ → Attach engine mounting -3- with securing bolts -1- and -2-.
• ‒ Tighten securing bolts -2- to
      20 Nm
  and securing bolts -1- to
      55 Nm.

• ‒ → Tighten counter weight securing nuts -2- to 30 Nm.
• ‒ Install ribbed belt => Page 13-16.
• ‒ Checking injection pump commencement of delivery:

=> Repair group 23; Servicing Diesel direct injection system; Dynamically checking and adjusting injection pump commencement of delivery.