You should have said you were doing this Niel?
Copyright Autodata.
Seat Cordoba (99-02) 1,9D TDI 1999-02 Engine code: ALH
Timing belt - Renew Every 60000 miles or 48 months
Repair Time: Remove and install 2,20
Special Tools
Camshaft setting bar - SEAT No.T20038.
Injection pump locking pin - SEAT No.U-40074.
Two-pin wrench - SEAT No.U-30009.
Removal
Remove:
Engine top cover.
TDI: Intercooler to intake manifold hose.
SDI: Air hose to air filter.
SDI: Inlet manifold upper chamber.
Leon/Toledo: Coolant expansion tank. DO NOT disconnect hoses.
Leon/Toledo: PAS reservoir. DO NOT disconnect hoses.
Raise and support front of vehicle.
Remove:
Leon/Toledo: Front bumper.
Leon/Toledo: RH headlamp.
Timing belt upper cover Fig. 1.
Vacuum pump.
Engine undershield (if fitted).
Auxiliary drive belt.
Turn crankshaft clockwise to TDC on No.1 cylinder.
Ensure timing marks aligned Fig. 2.
Fit setting bar to rear of camshaft Fig. 3. Tool No.T20038.
Centralise camshaft using feeler gauges Fig. 4.
Lock injection pump. Use tool No.U-40074 Fig. 5.
Remove bolts one at a time from injection pump sprocket Fig 6. Fit new bolts. Tighten bolts finger tight.
NOTE: DO NOT slacken injection pump hub nut.
Leon/Toledo: Support engine.
Leon/Toledo: Remove:
RH engine mounting bolts Fig. 7, Fig. 8 & Fig. 9.
RH engine mounting.
Leon/Toledo: Raise engine slightly.
Leon/Toledo: Remove:
Engine mounting bracket bolts Fig. 10.
Engine mounting bracket.
Crankshaft pulley bolts Fig. 11.
Crankshaft pulley Fig. 12.
Timing belt centre cover Fig. 13.
Timing belt lower cover Fig. 14.
Slacken tensioner nut Fig. 15.
Turn tensioner anti-clockwise away from belt.
SDI: Use Allen key.
TDI: Use tool No.U-30009.
Lightly tighten tensioner nut Fig. 15.
Remove timing belt.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
Installation
IMPORTANT: Timing belt width must not be less than 22 mm.
Ensure timing marks aligned Fig. 2.
Ensure camshaft setting bar fitted correctly Fig. 3.
Ensure locking pin located correctly in injection pump Fig. 5.
Slacken camshaft sprocket bolt 1/2 turn Fig. 16.
NOTE: DO NOT use setting bar to hold camshaft when slackening sprocket bolt
Loosen sprocket from taper using a drift through hole in timing belt rear cover Fig. 17.
Remove:
Camshaft sprocket bolt Fig. 16.
Camshaft sprocket.
Align injection pump sprocket with bolts in centre of slotted holes Fig. 6.
Fit timing belt in following order:
Crankshaft sprocket.
Guide pulley G1.
Water pump sprocket.
Injection pump sprocket.
Guide pulley G2.
Tensioner pulley.
Guide pulley G3.
NOTE: Turn injection pump sprocket slightly to engage timing belt teeth.
Ensure belt is taut between sprockets.
Fit camshaft sprocket to belt, then install camshaft sprocket with belt onto end of camshaft.
Fit camshaft sprocket bolt Fig. 16.
Lightly tighten camshaft sprocket bolt Fig. 16. Sprocket should turn freely without tilting.
Slacken tensioner nut Fig. 15.
Turn tensioner pulley clockwise as follows:
SDI: Until pointer and notch in baseplate aligned Fig. 19. Use Allen key.
TDI: Until notch and raised mark on tensioner aligned Fig. 18. Use tool No.U-30009.
If tensioner pulley turned too far: Turn fully anti-clockwise and repeat tensioning procedure.
Tighten tensioner nut to 20 Nm Fig. 15.
Ensure timing marks aligned Fig. 2.
Tighten camshaft sprocket bolt Fig. 16. Tightening torque: 45 Nm.
NOTE: DO NOT use setting bar to hold camshaft when tightening sprocket bolt.
Temporarily tighten injection pump sprocket bolts Fig. 6. Tightening torque: 20 Nm.
NOTE: DO NOT tighten further 90°.
Remove:
Camshaft setting bar Fig.18298.3.
Injection pump locking pin Fig.18298.5.
Turn crankshaft two turns clockwise until timing marks aligned Fig. 2.
Ensure camshaft setting bar can be fitted Fig. 3.
Ensure locking pin can be inserted in injection pump Fig. 5. Tighten bolts further 90° Fig. 6.
If not: Slacken injection pump sprocket bolts Fig. 6. Turn sprocket hub until locking pin can be inserted Fig. 5. Tighten bolts to 20 Nm + 90° Fig. 6.
Ensure notch and raised mark on tensioner aligned Fig. 18.
If not: Repeat tensioning procedure.
Apply firm thumb pressure to belt. Tensioner marks should move out of alignment Fig. 18 or Fig. 19.
Release thumb pressure from belt:
SDI: Tensioner marks should move back following movement of belt.
TDI: Tensioner marks should realign.
NOTE: SDI: Tensioner marks will not realign
Leon/Toledo: Install:
RH engine mounting bracket.
RH engine mounting bracket bolts Fig. 10.
Leon/Toledo: Tighten RH engine mounting bracket bolts Fig. 10. Tightening torque: 45 Nm.
Leon/Toledo: Fit and align RH engine mounting:
Engine mounting clearance: 14 mm Fig. 20.
Engine mounting clearance: 10 mm minimum Fig. 21.
Ensure engine mounting bolts Fig. 7 aligned with edge of mounting Fig. 22.
Leon/Toledo: Tighten:
Engine mounting bolts Fig. 9. Tightening torque: 40 Nm + 90°. Use new bolts.
Engine mounting bolts Fig. 7. Tightening torque: 60 Nm + 90°. Use new bolts.
Engine mounting bolts Fig. 8. Tightening torque: 25 Nm.
Tighten crankshaft pulley bolts Fig. 11. Tightening torque: 10 Nm + 90°.
Install components in reverse order of removal.
