SEAT Workshop Service and Repair Manuals

Removing and installing the distribution chain of the control pump Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Gauge -VAS 6079-, see equivalent → Anchor

t	Extractor -T10094 A-, see equivalent → Anchor

t	Dial gauge adaptor -T10170-, see equivalent → Anchor

t	Camshaft clamp -T10171 A-, see equivalent → Anchor.

t	Hose clamp -T10172-, see equivalent → Anchor

t	Pin -T40011-, see equivalent → Anchor

t	Spark plug spanner -3122 B-, see equivalent → Anchor

t	Hose clamp -3415-, see equivalent → Anchor

t	Hose clamp -3415/1-, see equivalent → Anchor

t	Torque wrench (5... 50 Nm) -V.A.G 1331-, see equivalent → Anchor

Distribution chain and oil pump drive chain, removal → Anchor Distribution chain and oil pump drive chain, installing → Anchor Removing –  Drain coolant → Chapter.

–  Disengage coolant hose -1- at engine cover panel. –  Pull out the dipstick.-2-. –  Unscrew bolts -arrows- and remove engine cover panel. –  Remove the cylinder 1 spark plug. To do so, use the extractor -T10094 A- and the spark plug spanner -3122 B- → Chapter.

–  Screw the adapter for dial gauge-T10170- into spark plug hole as far as the stop. –  Insert the dial gauge -VAS 6079- with extension -T10170/1- as far as the stop and secure using locking nut -arrow-. –  Turn the crankshaft in the direction of engine rotation to TDC cylinder 1 . Observe the position of the small pointer of the gauge.

–  Disconnect connector terminal -1- on the turbocharger divert valve -N249-. –  Unhook the hoses -2- on the pressure hose and open the cable guide -3-.

–  Disconnect the connector terminal -2- on the supercharger pressure sensor -G31- using the intake air temperature sensor 2 -G299-. –  Remove bolts -3-.

–  Press securing clips -1- outwards and pull pressure hose -2- upwards. –  Then disconnect the pressure hose -2- from the turbocharger.

–  Disconnect the coolant hoses on the coolant pipe -1- and unscrew the pipe on the camshaft casing and on the engine block from below. –  Unscrew the fastening bolts for the camshaft covers -2- and remove covers

The openings -arrows- of the camshafts should be in the positions shown. Where necessary, turn the crankshaft one turn (360°).   Note t  When the crankshaft rotates more than 0.01 mm beyond the TDC, the crankshaft must be rotated by approx. 45° against the direction of the engine again. Next, turn the crankshaft in the direction of engine rotation to TDC cylinder 1 . t  Permissible deviation from TDC cylinder 1: ± 0.01 mm

–  Fit the camshaft fastener -T10171 A- as far as possible into the openings in the camshaft. The locking pins -arrow 1- should fit in the openings -arrow 2-. The word „TOP“-arrow 3- should be legible from above.

–  Hand thread (without tightening ) an M6 bolt -arrow- to secure the camshaft fastener -T10171 A-.   Note Remember that there are different securing points for the camshaft fastener -T10171 A-. –  Remove distribution chain → Chapter.

–  Remove the cover -1- of the oil pump sprocket.

–  Push the tensioning rail by hand in the -direction of the arrow- and lock the piston of the chain tensioner using the retention tool -T40011-.

–  Mark the direction of rotation of the distribution chain -3- using a felt tip pen.   Note The securing bolt of the variator -2- is left-threaded. –  Remove bolts -2- and -4- and take out the variator -1- together with the distribution chain -3-. To lock, use the retention tool -T10172-.

–  Lock the oil pump sprocket using the retention tool -T10172- and undo the fastening bolt -1-.

–  Using a screwdriver, lever the tensioning spring -1- at the bolt -2- and remove the tensioning spring -1-. –  Loosen fastening bolt -3- and remove the chain tensioner. –  Mark the direction of rotation of the oil pump control chain -2- using a felt tip pen.

–  Undo the fastening bolts of the sprocket -1- and remove the sprockets -1- and -3- together with the oil pump control chain -2-. Installing l  The crankshaft must be located at TDC cyl. 1.

–  Move the sprocket -1- in the -direction of the arrow - as far as possible along the crankshaft journal.   Caution The cast-iron projection -2- on the sprocket -1- should fit into the groove -3- of the crankshaft journal.

–  Mark the positions of the sprocket and the crankshaft with respect to the cylinder head using a felt-tip pen.

–  Place the oil pump control chain -3- on the sprocket -1- and at the same time fit the sprocket -2- on the oil pump drive shaft.   Note t  Observe the mark showing the direction of rotation of the oil pump control chain. t  The oil pump drive wheel only fits in one position on the oil pump drive shaft -arrow-.

–  Lock the oil pump drive wheel using the retention tool -T10172-. –  Tighten the fixing bolts -1- to 20 Nm + 90°.

–  Place the chain tensioner on the oil pump control chain and tighten the securing bolt -3- to 15 Nm. –  Lever the tensioning spring -1- using a screwdriver at bolt -2-.   Note t  Observe the marks -arrows-. t  The crankshaft can not turn.

–  Bolt the sprocket -3- by hand using a new fastening bolt. –  Fit the distribution chain -1- on the crankshaft sprocket -4-, the exhaust camshaft sprocket -3- and hand tighten the variator -2- with a new fastening screw.   Note t  Observe the mark showing the direction of rotation of the distribution chain -1-. t  Check that the guide hose is fitted between the intake camshaft and the variator. t  The securing bolt of the variator -2- is left-threaded.

The distribution chain should rest on the guide rail -1- and on the crankshaft sprocket -arrow-.

–  Fit the chain tensioner -1- and tighten the securing bolts -2- to a torque of 9 Nm. –  Tension the distribution chain by removing the retention tool -T40011- from the tensioning device. –  Check that the marks on the crankshaft sprocket and the engine block match.

–  Tighten the fastening bolt -2- to a torque of 40 Nm and bolt -4- to a torque of 50 Nm (use retention tool -T10172-).   Note t  The fastening bolts -2- and -4- are tightened with a retightening angle of 90°, after checking the distribution timing t  The securing bolt of the variator -2- is left-threaded.

–  Undo bolt -arrow- and remove the camshaft fastener -T10171 A- from the camshaft casing. –  Check distribution timing → Chapter If timing is OK:

–  Lock the camshaft sprockets using the counter holder -T10172- and tighten the fixing bolts -2- (left-threaded) and -4- and tighten by 1/4 turn using a spanner.   Note t  The securing bolt of the variator -2- is left-threaded. t  The camshaft sprockets must not turn when tightening them onto the camshaft.

–  Fit the cover of the oil pump wheel -1-. –  Fit distribution casing → Chapter. –  Install crankshaft pulley → Chapter. –  Install poly V-belt → Chapter. –  Fill up with coolant → Chapter.

–  Hang the coolant hose -1- in at engine cover. –  Tighten securing bolts -arrows-to a torque of 10 Nm.