SEAT Workshop Service and Repair Manuals

Gearbox side

Special tools and workshop equipment required

t	Locating bolt -T10340-

t	Camshaft clamp -T10477-

t	Extractor tool -T20143/1-

t	Assembly tool -T10479-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1410-

Removal: –  Drain coolant → Chapter.

–  Press locking lugs -arrows- and pull intake connection off -1- in -direction of arrow-. –  Disconnect hose -1- at air cleaner housing.

–  Pull air filter housing upwards off studs at positions -2- and -3-.

–  Unlock and disconnect fuel supply line -1- and breather line -2-. → Fuel supply system - Petrol engines; Rep. gr.20. –  Open line guide -3- and detach hoses. –  Seal lines so that fuel system is not contaminated by dirt. –  Detach clamps -arrows-.

–  Unscrew securing bolt -1- and remove cover -2-. –  Undo and remove bolts -arrows-.

–  Unclip duct from the guard. –  Remove cover -1- and cover -2-.

–  Disconnect all coolant hoses -1- from coolant pump.

–  Unscrew plug -arrow- from crankcase. –  Lower lifting platform completely.   Note t  The lifting platform must be lowered completely in order to allow for screwing the locking pin -T10340- into the crankcase. t  The locking pin is installed from above. t  When the vehicle is raised, the hole is hidden behind the drive shaft.

–  Screw locking pin -T10340- into crankcase from above as far as it will go.   Caution If locking pin -T10340- cannot be screwed in as far as stop, this indicates that crankshaft is not in the correct position! In this case, proceed as follows. –  Unscrew locking pin. –  Turn crankshaft 90° in direction of rotation of engine. –  Screw locking pin -T10340- into crankcase as far as it will go. –  Tighten locking pin -T10340- to 30 Nm. –  Turn crankshaft in direction of rotation of engine as far as the stop. Locking pin -T10340- locks crankshaft in direction of engine rotation.

Marked gap -1- of camshaft adjuster -3- is aligned with lug -2- of camshaft housing.

Marked tooth -1- of exhaust camshaft sprocket -3- is aligned with lug -2- of camshaft housing.

–  Grooves -1- of inlet camshaft -3- are positioned right above horizontal camshaft centre line -2-. –  Grooves -1- of exhaust camshaft are positioned right above horizontal camshaft centre line -2-.

–  Recesses of gear -3- in area of grooves are slightly more oriented above horizontal camshaft centre line.   Caution The camshaft clamp -T10477- must slide into position easily. The camshaft clamp must not be positioned using any kind of hammer.

–  Insert camshaft clamp -T10477- to stop into camshafts and tighten bolt -arrow- by hand.

–  Mark position of coolant pump gear -1- with a marker -2- at lug -3-.   Note t  The marking will be used for installing the gear at the correct position at a later point. t  Otherwise the camshaft clamp -T10477- cannot be inserted. –  Remove retaining ring -arrow- of gear selector cable.

–  Remove gear selector cable -1- from selector lever and lay to side.

–  Unscrew securing bolts -1- through -5- of coolant pump in sequence given. –  Remove coolant pump.

–  Unscrew bolt -arrow- and remove camshaft clamp -T10477- from camshafts. –  Remove toothed belt -1- from coolant pump toothed belt pulley.

–  Secure toothed belt pulley -2- with counterhold -T10172- and unscrew securing bolt -1-. –  Remove toothed belt pulley.

–  Carefully fit extractor hook -T20143/1- between camshaft and seal -1-. –  Lever out seal -1-. Installation

–  Put together assembly sleeves -T10479/2- and -T10479/3-. –  Fit new seal in -direction of arrow- onto assembly sleeve -T10479/2-.

–  Disconnect assembly sleeves -T10479/2- and -T10479/3- in -direction of arrow-.

–  Fit assembly sleeve -T10479/2- with seal -1- on camshaft. –  Fit thrust piece -T1047971- onto assembly sleeve and draw it in to stop with securing bolt -2-. –  Mount toothed belt pulley -2- on camshaft with securing bolt -1-.

Marking on toothed belt pulley must be aligned with lug. –  Secure toothed belt pulley -2- with counterhold -T10172-. –  Tighten securing bolt -1- to 20 Nm. –  Fit toothed belt centrally onto camshaft sprocket and coolant pump toothed belt pulley. –  Mount coolant pump on cylinder head with securing bolts.   Caution Always adhere to the sequence of work steps given below when installing the coolant pump. This ensures that the toothed belt is correctly tensioned. The following work steps should be carried out with the aid of a 2nd mechanic. –  At first, tighten securing bolts to 5 Nm. –  Then, loosen all bolts by 90°. –  Preload coolant pump with hexagon socket insert -6- and torque wrench -V.A.G 1331- to 33 Nm.

–  Keep torque wrench -V.A.G 1331- pushed to that torque. –  Tighten securing bolts -1- through -5- in sequence given to 20 Nm.   Caution After completing work, it is essential to ensure that the locking pin -T10340- and the camshaft clamp -T10477- have been removed. Tightening torque of the cylinder block oil filler neck: 30 Nm Further assembly is basically the reverse of the dismantling sequence. –  Install selector mechanism to gearbox → Rep. gr.34. –  Fill up with coolant → Chapter. –  Install air cleaner housing → Chapter.