SEAT Workshop Service and Repair Manuals

Camshafts and camshaft adjuster: Removing and installing t  Removing → Anchor. t  Installing → 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  Hose clamp -3036-, see equivalent → Anchor

t  Socket -3366-, see equivalent → Anchor t  Sealant for joints → Spare parts catalogue Removing –  Place the lock carrier plate into service position → Bodywork, exterior fitting work; Rep. gr.50 –  Remove the timing belt from the cogwheel of the camshaft → Chapter. –  Rotate the crankshaft by approx. 45° in the opposite direction to the direction of rotation using a spanner in the fixing bolts of the camshaft gear wheels so that no piston is positioned in the TDC.

–  Loosen the sprocket of the cam shaft with the counter holder -3036-. –  Remove the sprocket from the camshaft.

–  Separate the plug connections -arrow- of the valve 1 for cogwheel adjustments -N205-. –  Remove cylinder head cover → Chapter –  Detach both oil deflectors.

–  Separate the plug connections -arrow- of the Hall sensors -G40-. –  Remove Hall sender housing and also washer and rotor for Hall sender.

–  Check TDC position of camshafts again: l  The two marks on the camshafts must be opposite the two arrows on the bearing caps. If old drive chain is to be reused: –  Clean drive chain and chain sprockets of camshafts at the points opposite the two arrows on the bearing caps and make coloured mark to identify installation position.

l  Gap between the two arrows/coloured marks = 16 drive chain rollers l  The notch on the exhaust camshaft has a slight inward offset with respect to chain roller -1-.   Note Do not mark chain by way of centre punch, notch or the like. Continue for all chains:

–  Lock the camshaft adjuster with the retainer -3366-.   Note Over-tightening holder for chain tensioner can damage camshaft adjuster.

–  First remove bearing caps -3- and -5- on inlet and exhaust camshafts. –  Remove double bearing cap. –  Remove the two bearing caps next to the chain sprockets on the inlet and exhaust camshafts. –  Unscrew securing bolts for camshaft adjuster. –  Remove the bearing cover -2- and -4- of the inlet and exhaust camshafts crosswise, one after another. –  Remove inlet and exhaust camshafts with camshaft adjuster. Installing l  Pistons must not be at TDC.

–  Replace rubber metal gasket for camshaft adjuster and apply a thin coat of sealant to the -hatched area- → Spare parts catalogue.

–  Position drive chain as follows on camshaft chain sprockets: If old drive chain is re-used: –  Adjust the colour markings -arrows- so they are aligned. If new drive chain is being used:   Caution t  The number of rollers stated is only intended as a guide for fitting the chain on the camshafts. t  Make sure that the arrows on the bearing caps and the notches on the camshafts align when installing camshafts (with drive chain) in cylinder head → Anchor.

l  The distance between notches -A- and -B- on the camshafts must be 16 drive chain rollers. The illustration shows where the -1st- and the -16th- roll should be placed for the chain sprockets. l  Notch -A- is offset slightly towards the inside in relation to chain roller -1-. Continue for all chains: –  Insert camshaft adjuster into the drive chain (2nd mechanic required). –  Insert camshafts with drive chain and camshaft adjuster into cylinder head. –  Oil the camshaft running surfaces. l  Bearing cap and camshaft adjuster dowel sleeves must be fitted in cylinder head.   Note When installing bearing caps ensure that the identification mark is readable from the inlet side of cylinder head. –  Secure camshaft adjuster (watch position of dowel sleeves).

–  Tighten the bearing caps -2- and -4- on inlet and exhaust camshafts alternately and in diagonal sequence (pay attention to the dowel sleeves). –  Install the two bearing caps next to the chain sprockets on the inlet and exhaust camshafts. –  Remove the retainer -3366-. –  Check camshafts are positioned correctly.

l  The two marks on the camshafts must be opposite the two arrows on the bearing caps -arrows-.   Note If necessary, turn camshaft slightly backwards or forwards so that the two marks coincide.

–  Apply a small quantity of sealant to the hatched area of the double bearing cap and the outer bearing cap adjacent to the camshaft adjuster; Sealant → Parts catalogue. –  Install remaining bearing caps (pay attention to dowel sleeves). –  Replacing the gaskets of the cam shafts : or . → Chapter „Exhaust camshaft oil seal: replacing“ or → Chapter „Renewing inlet camshaft oil seal“. –  Torque down remaining bearing caps. –  Mounting the cam shaft sprocket.

l  Note the fitting position: Not installation position: The narrow path of the cam shaft sprocket points outwards-arrows- and the OT marking is visible.

–  Tighten the fastening screw of the cam shaft sprocket (use the counter holder -3036- for this). –  Install Hall sender → Item. –  Install cylinder head cover → Chapter. –  Rotate the crankshaft by approx. 45° in the direction of rotation using a spanner in the fixing bolts of the camshaft gear wheels to position the piston back in the TDC. –  Install toothed belt (adjust valve timing) → Anchor. –  Install poly V-belt → Chapter.   Note t  After installing camshafts, wait for approx. 30 minutes before starting engine. The hydraulic elements should be allowed to sit in place (if not, the valves may press on the cylinder). t  After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated. –  Assemble the lock carrier with attachments → Bodywork - Exterior assembly work ; Rep. gr.50.

–  The torque reaction support must set itself on its rubber stop by means of its self weight, then tighten the nuts -arrows-. Tightening torque → Chapter „Assembly mountings - exploded view“ –  Fit the front bumper trim → Bodywork, exterior fitting work; Rep. gr.63. –  Check headlight adjustment → Booklet301. Tightening torques

Component	Nm
Bearing cap to cylinder head	10
Camshaft adjuster to cylinder head	10
Rotor for Hall sender to camshaft	25
Hall sender housing to cylinder head	10
Sprocket of the camshaft on the camshaft	65
Stop for torque reaction support to lock carrier	28