SEAT Workshop Service and Repair Manuals

Removing –  Remove intake hose between air cleaner and throttle valve housing using pliers -T20029- for spring-type clips. –  Remove throttle valve housing → Chapter. –  Remove cover for intake pipes: → Chapter –  Remove upper toothed belt guard and cylinder head cover.

–  Turn crankshaft to TDC No. 1 cylinder -arrow-. Engine removed:

–  Install adjustment device -U-20010- as shown. –  Set adjustment device to 38 mm -arrow A-. –  Turn crankshaft until flywheel TDC marking aligns with point of setting device -arrow B-.

–  Lock camshaft with setting bar -U-40021-. –  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.

–  Hook extension -U-30025/2- into bracket on lower right of cylinder block.

–  Fit support bracket -U-30025- (with legs) and support engine, in installation position with extension -U-30025/2-.

–  Remove right-hand engine assembly mounting complete -arrows-. –  Remove engine mounting on cylinder block.

–  Lock injection pump sprocket with pin -U-20003-.

–  Loosen tensioning roller nut -arrow-. –  Relieve tooth belt tension and take off camshaft and injection pump sprockets. –  Remove injection pump sprocket securing nut. –  Pull pin -U-20003- out from injection pump sprocket.

–  Loosen puller -U-20001- arms and offer up. –  Locate puller arms through holes in injection pump sprocket and tighten. –  Place injection pump sprocket under tension with puller. –  Release injection pump sprocket from injection pump taper by tapping on spindle of puller -arrow- (thereby hold sprocket so that it does not fall off). –  Remove fuel supply and return pipes from injection pump. –  Remove injection pipes with spanner -U-40072-.   Note! t  Use spanner -U-40072- to loosen injection pipes. t  Always remove pipework complete, do not alter shape. t  Cover openings with clean cloths. t  Also ensure that no diesel fuel runs onto the coolant hoses. If necessary hoses must be cleaned immediately. Affected hoses must be replaced.

–  Separate 10-pin connector -arrow- (connection to injection pump metering adjuster) and unclip connetor from retainer.

–  Remove securing nuts/bolt from console -arrows-.

–  Then remove bolt from rear support -arrow-. –  Take off injection pump.