SEAT Workshop Service and Repair Manuals

Installing –  Insert injection pump into console and then tighten securing bolt on rear support with conical nut first. –  Insert front securing bolts and tighten to 25 Nm.

–  Fit injection pump sprocket to hub with new bolts -arrows- but do not tighten. –  Align injection pump sprocket to central position in elongated holes. –  Lock injection pump sprocket with pin -U-40074-. –  Loosen camshaft sprocket securing bolt a half turn.   Note! Loosen and tighten bolt securing camshaft with tool -T20018-; never use adjustment ruler as countersupport.

–  Place a drift through hole in the rear of the toothed belt guard and release the camshaft sprocket from camshaft taper with a blow from a hammer. –  Take camshaft sprocket off. –  Check whether TDC mark on flywheel and reference mark are aligned. –  Place tooth belt on injection pump sprocket and tensioning roller. –  Fit camshaft sprocket into toothed belt and secure sprocket so that the camshaft can still turn.

Engine codes AGP, AQM –  Tighten toothed belt. To do so, apply a hexagonal spanner for commercial use to the eccentric and turn clockwise until the arrow and notch coincide.

Engine codes AGR, ALH, ASV –  Tighten the toothed belt. To do so, turn the nut spanner -U-30009 A- by the eccentric clockwise until the notch and protuberance -arrows- coincide. Continue for all engine codes   Note! t  If the eccentric has been turned too far the tensioner roller must be relieved completely and retensioned. The eccentric must never be turned back when it has been turned too far.

t  Ensure retaining hook is correctly seated in toothed belt guard. –  Tighten securing nut to 20 Nm. –  Check TDC mark on flywheel again. –  Tighten new securing bolts for injection pump sprocket to 20 Nm.   Note! t  After dynamically checking the injection timing the bolts must be tightened a further 1/4 turn (90°). t  The securing bolts must only be used once as these a stretch bolts. –  Tighten camshaft sprocket securing bolt to 45 Nm. –  Remove locking pin -U-40074-. –  Remove setting bar -T20038- from camshaft.. –  Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again. –  Reconnect injection pipes, fuel supply pipe and electrical wiring.

–  Fill injection pump with Diesel as follows. –  Screw adapter -V.A.G 1318/10- into injection pump return supply opening. –  Connect hand vacuum pump -SAT 1390- with approx. 1 m transparent plastic hose to adapter. –  Operate vacuum pump until fuel flows out of return supply opening. Do not draw fuel into vacuum pump. –  Remove adapter and connect return supply pipe. –  Install cylinder head cover and vacuum pump. Engine codes AGP, AQM –  Install upper part of intake manifold → Item. Engine codes AGR, ALH, ASV –  Install connecting hose between intercooler and intake manifold. Continue for all engine codes –  Dynamically check commencement of injection and adjust if necessary → VAS 5051.