SEAT Workshop Service and Repair Manuals

Notes:

• ◆ When stripping and assembling the engine it should be secured to the engine frame with engine bracket 3269.
• ◆ If when repairing an engine, metal shavings or large quantities of small metal particles -caused, for example, by partial seizure of crankshaft and conrod bearings- are found in engine oil, to prevent consequential damage, apart from thoroughly cleaning oil passages, it is necessary to renew all oil spray jets, the oil non-return valve and the oil cooler.

I    

II    

III    

Part I

• Camshaft chain sprocket
• ◆ Removing and installing
  , removing and installing camshafts
• Sender wheel
• ◆ For Hall sender (G40)
• ◆ Contact surface of timing chain and sender wheel must be dry when installing
• ◆ Removing and installing
  => Page 15-26, Removing and installing camshafts
• 100 Nm
• ◆ Oil bolt head contact surface when installing
• ◆ To remove and install counter-hold with 24 mm open jaw spanner on camshaft => Page 15-26, removing and installing camshafts
• Pivot pin, 25 Nm
• ◆ For tensioning plate item 7
• Seal
• ◆ Renew

• Chain tensioner, 30 Nm
• ◆ For camshaft chain item 9
• ◆ Up to engine number:
  AAA 217000 with oil drilling for double chain
• ◆ Bleed before installing
  => Fig. 3
• ◆ From engine number:
  AAA 217001 without oil drilling => Fig. 2
• ◆ Only rotate engine when chain tensioner is installed
• Tensioning plate
• ◆ For camshaft chain item 9
• ◆ Up to engine number:
  AAA 217000 for double chain
• ◆ From engine number:
  AAA 217001 for single chain

• Sprocket
• ◆ For single chain Pos. 15
• ◆ Installing => Page 13-26, adjusting valve timing
• Camshaft chain
• ◆ Mark D.O.R. before removing (installation position)
  => Fig. 1
• ◆ Installing => Page 13-26, adjusting valve timing
• ◆ Up to engine number:
  AAA 217000 double chain
• ◆ From engine number:
  AAA 217001 single chain
• 100 Nm
• Sprocket
• ◆ From engine number:
  AAA 217001 for single chain
• ◆ Installing => Page 13-26, adjusting valve timing
• 10 Nm

• Chain tensioner with tensioning plate
• ◆ For single chain Pos. 15
• ◆ Before installing release locking spline in chain tensioner with a small screwdriver and press tensioning plate against chain tensioner
• ◆ Only rotate engine with chain tensioner installed
• Crankshaft sprocket
• ◆ Integral part of crankshaft
• ◆ Ground down tooth aligned with main bearing joint = TDC No. 1 Cyl.
  => Page 13-26, adjusting valve timing
• Single chain
• ◆ Mark D.O.R. before removing (installation position)
  => Fig.1
• ◆ Installing => Page 13-26, adjusting valve timing

• Guide rail
• ◆ For single chain Pos. 15
• ◆ Remove together with single chain
  => Page 13-26, adjusting valve timing
• Locating pin without collar, 25 Nm
• ◆ For guide rail item 16
• Locating pin with collar, 25 Nm
• ◆ For guide rail item 21
• 20 Nm
• ◆ Insert with locking fluid "D6"
• 20 Nm
• Guide rail
• ◆ For double chain item 9
• 10 Nm
• ◆ Insert with locking fluid "D6"
• Thrust washer
• Intermediate shaft

→ Fig.1    Marking single and double chains

• ‒ Mark single and double chains before removing (e.g. with paint, arrow pointing in D.O.R.).

Notes:

• ◆ From engine number AAA-217001 camshaft drive single chains only are installed.
  Therefore the chain tensioner has no oil drilling and must not be bled => Fig.2 .
• ◆ The single chain with new chain tensioner must only be installed in conjunction with a suitable tensioning plate.
• ◆ Do not mark chain with a punch mark, notch or similar!

→ Fig. 2    Camshaft chain tensioner

• ◆ The chain tensioner -A- with oil drilling (arrow) must only be installed with the double chain.
• ◆ The chain tensioner -B- must only be installed with the single chain.

→ Fig. 3    Bleeding double chain chain tensioner

• ‒ Push a piece of wire (ø0.8 mm) through the hole of the pressure piston -arrow- up to ball valve and press pressure piston and housing together onto stop.

Note:

If the pressure piston moves out again, repeat bleeding procedure.

Part II

• 5 Nm
• Cover
• ◆ Over intake manifold upper part
• 25 Nm
• H.T. cable guide
• Rear left support
• ◆ Between intake manifold upper part and cylinder head
• ◆ With engine earth connection
• Support bracket
• ◆ For accelerator cable
• Cap
• Gasket
• ◆ Renew if damaged
• Crankcase breather valve
• ◆ Arrow on heater element points to intake hose

• 10 Nm
• Cylinder head cover
• ◆ Removing and installing
  => Page 15-10
• O-Ring
• ◆ Renew
• ◆ Coat with oil before assembling and insert in camshaft sprocket cover Pos. 13
• Camshaft sprocket cover
• ◆ Can be removed and installed with cylinder head fitted
• ◆ Coat sealing surfaces with AMV 188 001 02
• ◆ If only the camshaft sprocket cover has been removed, prepare cylinder head gasket for assembly
  => Page 15-9, Fig. 2

• Chain tensioner, 30 Nm
• ◆ For double chain
• ◆ Bleed before installing
  => Page 13-8, Fig. 3
• ◆ From engine number:
  AAA 217001 without oil drilling => Fig. 2
• ◆ Only turn engine with chain tensioner installed
• Seal
• ◆ Renew
• Bracket
• ◆ For 42-pin connector and pump for coolant continued circulation
• Ignition transformer (N152)*
• ◆ Checking:

=> Repair Group 28; Servicing ignition part

• Bracket
• ◆ For electric wires

• Thermostat housing
• ◆ Dismantling and assembling => Page 19-11
• O-ring
• ◆ Renew
• Cylinder head gasket
• ◆ Renew
• ◆ If replaced renew the complete
  coolant
• Cylinder head
• ◆ Removing and installing
  => Page 15-1
• ◆ If replaced renew the complete
  coolant
• Cylinder head bolt
• ◆ Renew
• ◆ Note sequence when loosening and tightening
  => Page 15-13, installing cylinder head

• Lifting eye
• ◆ Secondary air inlet valve (N112) secured by bracket to lifting eye => Page 26-24, Removing and installing parts of secondary air system
• Intake manifold - lower part
• Gasket for intake manifold lower part
• ◆ Renew
• Ribbed belt tensioner
• ◆ Removing and installing ribbed belts => Page 13-22
• Cylinder head cover gasket
• ◆ Renew if damaged
• ◆ Note fitting position
• Bracket
• ◆ For fuel pipes

• Gasket for intake manifold upper part
• ◆ Renew
• Intake manifold upper part
• ◆ First tighten intake manifold lower part, then the two rear supports, Pos. 5 and 33
• Vacuum hose
• ◆ From brake servo
• Rear right support
• ◆ Between intake manifold upper part and cylinder head

Part III

• 10 Nm
• Oil pump drive cover
• O-ring
• ◆ Renew
• ◆ Oil before assembling
• Oil pump drive
• Cylinder block
• ◆ Removing and installing sealing flange and flywheel/drive plate => Page 13-37
• ◆ Removing and installing crankshaft => Page 13-46
• ◆ Dismantling and assembling pistons and conrods
  => Page 13-49
• Intermediate shaft

• Thrust washer
• 10 Nm
• ◆ Insert with locking fluid "D6"
• Knock sensor 2 (G66)
• ◆ Checking:

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

• 20 Nm
• ◆ Tightening torque influences the function of the knock sensor
• O-ring
• ◆ Renew if damaged
• Engine speed sender (G28)
• ◆ Checking:

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

• Gasket
• ◆ Renew if damaged
• ◆ Before fitting gasket coat sump flange/cylinder block flange with "D2"
• Coolant pipe
• ◆ To thermostat housing
  , Pos. 19
• ◆ Removing and installing
  => Page 19-6, parts of cooling system - engine side
• O-ring
• ◆ Renew
• Oil pump
• ◆ Dismantling and assembling => Page 17-11
• ◆ Coat oil pressure pipe on cylinder block and oil pump housing with AMV 188 001 02
• 25 Nm

• 10 Nm
• ◆ Renew
• ◆ Insert with locking fluid "D6"
• Seal
• ◆ Renew
• Oil drain plug, 30 Nm
• 15 Nm
• Sump
• ◆ Clean sealing surface before installing
• Oil cooler cover, 25 Nm
• Oil cooler
• ◆ Coat contact area outside the seal with AMV 188 100 02
• ◆ Ensure clearance to adjacent components
• ◆ See note
  => Page 13-1

• Oil filter housing
• ◆ Dismantling and assembling
  => Page 17-8
• Gasket
• ◆ Renew
• ◆ Note fitting position
• ◆ Oil before installing
• Vibration damper
• ◆ Removing and installing ribbed belt => Page 13-22
• 120 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Counter-hold with 3273 to loosen and tighten =>Fig. 1
• Coolant pump
• ◆ Check for ease of movement
• ◆ Removing and installing
  => Page 19-19

• 20 Nm
• Pulley
• ◆ For coolant pump
• 25 Nm
• ◆ Use V.A.G 1590 to loosen and tighten
• ◆ Modify water pump spanner V.A.G 1590
  => Page 19-10, Fig. 1
• 60 Nm
• Guide tube
• ◆ Secure with bolt to inlet manifold lower part
• Right engine bracket
• Dipstick
• ◆ The oil level must not be above the max. mark!

• Oil non-return valve, 5 Nm
• ◆ Note fitting position
• ◆ Clean if badly soiled
• ◆ See note
  => Page 13-1

→ Fig.1    To loosen and tighten the securing bolt hold vibration damper with counter-hold tool 3273

Notes:

• ◆ Renew securing bolt.
• ◆ When tightening the securing bolt the crankshaft must not turn.