SEAT Workshop Service and Repair Manuals

Toothed belt: removing, fitting, tensioning t  Removing → Anchor t  Installing → Anchor. t  Tightening torques → Anchor Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	Crankshaft stop -T10100-, see equivalent

t	Locking bolt -T10115-, see equivalent → Anchor

t	Hose clamp -T20018B-, see equivalent → Anchor

t	Hose clamp -T20102-, see equivalent → Anchor

t	Base -T20174-, see equivalent → Anchor

t	Hose clamp -T10050-, see equivalent → Anchor

t	Hose clamp -T20167-, see equivalent → Anchor

t	Turning tool -T20197-, see equivalent → Anchor

t	Socket -U 30025E-, see equivalent → Anchor

Note

For engines before the 2004 model, the tension roller for the timing belt does not have an interior hexagon for the Allen key. In these cases use the tool -T20197- to loosen and tighten the timing belt. Removing   Note Adjustment work on the timing belt should only be done when the engine is cold, given that the position of the indicator arm on the tension device will vary depending on the engine temperature.

–  Remove noise insulation: → Bodywork, exterior fitting work; Rep. Gr.50

–  Loosen the spring-type clamp -arrow- with pliers -T20174- and remove the pipe from the turbocharger.

–  Remove the engine sound proofing cover, pulling upwards forcefully (-arrows A-) and remove forwards, from the rear attachment (-arrow B-). Engine code BMT

–  Detach the outer -1- and inner -2- engine covers, by pulling them evenly upwards. All vehicles (continued)

–  Remove supercharging tube -1- with connecting hose -2-, releasing the flanges -arrows- in doing so.

–  Remove the breather hose for the crankshaft sump -6- from the air conduction pipe. –  Leave the hoses for low pressure loose. –  Open the spring-type clamp -5- and remove the hose leading to the air filter. –  Unscrew bolts -1 and 2-. –  Separate air conduit from the vehicle -4-. –  Remove Poly V-belt → Chapter. –  Remove the retention tool of the tensioning device and leave it in rest position. –  Remove the front right wheel housing moulding: → Bodywork, exterior fitting work; Rep. Gr.66 –  Remove the supercharger air pipe between the intercooler and the turbocharger → Chapter. –  Remove vibration damper / belt pulley. –  Remove notched belt guard centre and lower parts. –  Remove the coolant expansion tank (without removing the hoses).

–  Position the engine and gearbox support tool -U-30025E- on the vehicle and suspend the engine in the fitting position.

–  Release the securing bolts -arrows- of the engine assembly.

–  Extract the bolts securing the engine support to the cylinder block -arrows-.   Note t  To loosen the upper two nuts on the engine bracket, the engine must be lifted slightly with the suspension device. t  To loosen the bottom nut on the engine bracket, the engine must be dropped slightly with the suspension device.   Note Insert the oval wheels of the toothed belt of the crankshaft in stages. When fitting these types of wheels, the crankshaft must be blocked using thecrankshaft stop -T10100- or the crankshaft stop -T10050- to be able to determine the TDC.

Distinctive characteristics of the crankshaft timing belt wheel. A = Conventional timing belt wheel, lock using the crankshaft stop -T10050-, mark the TDC in the 12 o'clock position A = Oval timing belt wheel, lock using the crankshaft stop -T10100-, mark the TDC in the 1 o'clock position   Note t  The engine can only be rotated by the crankshaft. t  The marks on the notched belt crankshaft sprocket -2- and the tool -1- must coincide. –  Crankshaft at TDC cyl. 1 TDC.

Vehicles with round wheel for the crankshaft timing belt –  Immobilise the notched belt crankshaft sprocket, with the retention tool -T10050-. To do this, insert the tool into the sprocket face and slide it until it enters into the hole in the sealing flange.

Vehicles with an oval wheel for the crankshaft timing belt –  Secure the wheel hub using the crankshaft stop -T10100-, the tabs -1- of the sprocket must coincide with the marking -2- for this purpose.   Note In the illustration the camshaft sprocket is shown without notched belt.

–  Lock the camshaft cog wheel with the counterhold -T20102-. The lugs -1- of the generator wheel should coincide with the arrow “4Z”-2- of the rear protection. –  Mark the toothed belt D.O.R. –  Unfasten nut of tensioning roller.

–  Loosen the attachment bolts -1- from the camshaft sprocket with the counterhold -T20018B- until the camshaft sprocket can turn loosely in the extended holes.   Note

For engines before the 2004 model, the tension roller for the timing belt does not have an interior hexagon for the Allen key. In these cases use the tool -T20197- to loosen and tighten the timing belt.

–  Unfasten nut of tensioning roller. –  Turn the off-centre adjustment with an Allen key -anti-clockwise- until the tension roller can be secured with the locking pin -T10115- .

–  Next turn the Allen key -in the direction of the arrow- as far as possible and hand tighten the fastening nut -1-. –  First remove the timing belt from the cooling liquid pump and then remove it from the other cogwheels. Installing .   Note t  Adjustment work on the timing belt should only be done when the engine is cold, given that the position of the indicator arm on the tension device will vary depending on the engine temperature.

t  Ensure that the tension roller is correctly located on the rear protection for the notched belt -arrow-. t  The tension roller should be fixed in the same position as for removal.

–  Rotate the camshaft cogwheel in its extended holes in the direction of the -arrow- to the limit. –  Position the notched belt on the crankshaft sprocket, the tension roller, the camshaft sprocket and then finally on the coolant pump sprocket.

–  Unfasten nut of tensioning roller. –  Turn the off-centre adjustment with an Allen key -anti-clockwise- until the locking pin -T10115- can be removed.

–  Rotate the tension roller -clockwise-, until the indicator arm is in a centre position of the plate groove -arrow- .   Note

When the attachment nuts are tightened, the pointer turns -arrow- from the opening of the base plate to maximum 5 mm to the right. This position should not be corrected, given that the belt sits into place with time.   Note t  Ensure that the attachment nut does not also rotate. t  Use the correct tightening torque to avoid damages to the engine when tightening the tensioner. –  Hold the tension roller in this position and tighten the tension roller nut to 20 Nm + 45° (1/8 turn).

–  Extract the counterhold -T20102-. –  Tighten the camshaft sprocket securing bolts -1- to 25 Nm, blocking any rotation using the counterhold -T20018B-. –  Remove the crankshaft stop -T10050- or the crankshaft stop -T10100-. –  Rotate twice, the crankshaft in the normal direction of rotation of the engine and position once again the distribution elements to TDC for the piston 1. –  Insert the crankshaft stop -T10050- or the crankshaft stop -T10100- into the wheel and allow it to slide until it engages in the sealing flange.   Note t  The crankshaft retention tool -T10050- must enter into the hole in the sealing flange while turning. t  The position for inserting the crankshaft stop cannot be adjusted by turning the crankshaft back. t  If the crankshaft has bee rotated beyond TDC for cylinder 1 and the crankshaft stop could not be pushed into the sealing flange at all, turn the crankshaft back a 1/4 turn so that the crankshaft can be placed back onto the TDC for cylinder 1 in the engines direction of rotation again. –  After inserting the crankshaft stop -T10050- or the crankshaft stop -T10100-, check if the camshaft wheel can be locked with the crankshaft stop -T20102-. Cannot be immobilised: –  Remove the stub of the retention tool -T10050- from the hole in the sealing flange and turn the crankshaft until the hub can be locked with the pin.

–  Loosen the bolts -1- that hold the camshaft wheel.

–  Turn crankshaft in the opposite direction of engine rotation until the crankshaft stop stub is just opposite the sealing flange hole -arrow-. –  Tighten the bolts of the camshaft cogwheel to 25 Nm. –  Remove the diesel injection pump locking pin -T20102- and the crankshaft stop -T10050- or the crankshaft stop -T10100-. –  Rotate the crankshaft twice in the normal direction of rotation so that the cylinder 1 is again at the TDC position. –  Repeat the previous verification.

–  Fit the engine bracket on the cylinder block and tighten the bolts -arrows- to 45 Nm.   Note All of the indicated bolts must be tightened for the engine bracket before fitting the engine and gearbox support assembly. –  Mount the engine assembly/bodywork brackets (replace the bolts). Tightening torques: 40 Nm 90° (1/4 rotation).

–  Secure the engine assembly support to the engine bracket, engine side, joining the contact surfaces with the aid of support tool -U-30025E-. Tightening torques: 100 Nm –  Install centre notched belt guard. –  Fit the lower notched belt protection and the vibration damper/belt pulley. –  Installing Poly-V belt → Chapter. –  Install top notched belt guard. –  Remove the support -U-30025E-. Continue with the installation following reverse order of removal instructions. Tightening torques

Component		Nm
Notched belt tensioning roller to cylinder head		20 + 45° 1)
Camshaft cogwheel to hub		25
Bottom section of notched belt guard to cylinder block		10 2)
Centre section of notched belt guard to cylinder block		10 2)
Damper to crankshaft sprocket		10 + 90° 3)4)
Engine mount to the engine block		45
Engine mount to engine console		30 + 90° 3)4)

1) 45° respective (1/8 turn) 2) Place with fixing agent; fixing agent → Spares parts catalogue. 3) Replace the bolts 4) 90° respective (1/4 turn)