SEAT Workshop Service and Repair Manuals

Camshaft housing: separation   Note t  In this engine the camshafts are housed in a casing. Therefore, the camshaft housing can only be removed after removing the distribution casing. t  The camshaft housing sealing surface must not be reworked. t  First check whether a coded radio is fitted. If this is the case consult the anti-theft coding.

–  Remove air filter → Chapter. –  With the ignition switched off, disconnect battery earth strap.

–  Remove the lower engine protection → Bodywork, exterior fitting work; Rep. gr.50. –  Remove the front right wheel housing moulding → Bodywork, Exterior fitting work ; Rep. gr.66.

–  Remove the engine speed sender -G28--arrow-.

–  Release earth cable -1- and Hall sensor connector -arrow-. –  Unclip connectors from ignition coils.

–  Remove the ignition coils -arrows-. To do so, use extractor -T10094-. –  Set the electrical installation to one side, held in the rear support of the camshaft casing and in the upper part of the camshaft casing.

–  Turn the crankshaft in the direction of engine rotation, using the pulley fastening bolt, until the counterhold -T10121- can fit into the aperture of the engine speed sensor -G28-.

–  Lock the crankshaft fitting the counterhold -T10121- in the aperture of the engine speed sensor -G28-. –  Mark direction of rotation of Poly-V belt and remove → Chapter. Vehicles with air conditioning/heating –  Follow the additional instructions and assembly work → Chapter.   Caution The air conditioning refrigerant circuit must not be opened. To avoid damage to the condenser and refrigerant pipes/sleeves, take care not to bend, twist or stretch the pipes/sleeves excessively.

–  Partially remove the air conditioning/climate control compressor and fasten it to the bodywork → Heating, air conditioning/climate control ; Rep. gr.87. All other vehicles continued –  Remove the alternator → Alternator; Rep. gr.27.

–  With the aid of tool -T20159- , lock the coolant pump pulley, remove the bolts -arrows- and the pulley. –  Loosen or separate the following components: l  Tensioning device for Poly-V belt → Item l  Idle roller → Item l  Oil level/oil temperature sender -G266- → Item l  Guide tube for the dip stick → Item l  Oil separator → Item   WARNING For safety reasons the fastening bolt of the crankshaft pulley must not be loosened or tightened with a pneumatic tool, as vibrations from the tool could provoke the displacement of the crankshaft gear and release it from the pin. This would cause major damage on starting the engine.

–  Immobilise the crankshaft pulley -2- with the counterhold -T20018B- and loosen the retaining bolt -1-. –  Extract the bolt -1- and remove the crankshaft pulley -2-. –  Remove sump → Chapter.

–  Fit the support -U 30025E- and pre-tighten slightly.

–  Remove the fixing bolts from the engine mounting -arrows-, to do so, partially separate the coolant expansion tank.

–  Remove fastening bolts from the distribution casing and the 3 bolts shown -arrows-. –  Remove casing from the distribution.

–  Remove the camshaft housing covers -arrows-.

–  Remove the counterhold -T10121- from the flywheel.

–  Turn the crankshaft with the securing bolt of the pulley in engine rotation direction until the grooves on both camshafts are horizontal.

–  The counterhold -T10123- should fit easily to the camshafts. –  Fit both counterholds tightening the M6 hexagonal bolts by hand.

–  Lock the crankshaft fitting the counterhold -T10121- in the aperture of the engine speed sensor -G28-.   Note If it is not possible to fit the counterhold -T10121-, remove the counterhold -T10123- from the camshafts. Turn the crankshaft in the direction of engine rotation (360º) and repeat the operation. If both securing tools cannot be fitted: –  Adjust distribution timing → Chapter. If both securing tools can be fitted: –  Remove the distribution chain from the camshaft sprockets → Chapter.

–  Loosen the camshaft housing bolts, from outside to inside, diagonally, in the order indicated. –  Carefully lift camshaft housing off. Remove camshafts

–  If it is necessary to remove the camshafts, loosen and remove the bolts to the camshaft bearings in the order shown. –  Carefully remove the camshafts. Fitting camshafts   Note The projection of the intake camshaft should be above the drill hole for the Hall sensor.

–  Manually tighten the camshaft bearing bolts in the sequence indicated. –  Tighten the new camshaft bearing bolts in the sequence indicated. Take care not to tilt the camshaft bearing caps. l  Tightening torque: 10 Nm + 1/4 turn (90º)