Tolerance Data 2009.

2 Seat, Toledo 1,6i

Tools

1. “V/159” = Belt tensioner tool.

1. “V/159” = Belt tensioner tool.

 Tolerance Data 2009.2 Seat, Toledo 1,6i

Dismount 1

1. Remove :
 the right front wheel.
 the right inner fender.
 the multi-belt.
2. Dismount upper timing belt cover.
3. Remove crankshaft pulley / vibration damper.
4. Dismount lower timing belt cover.
 Tolerance Data 2009.2 Seat, Toledo 1,6i

Dismount 2

1. Turn the engine clockwise to the marks.

2. Marks on the crankshaft pulley / vibration damper must match the marks on the timing belt cover.
3. Rotor in the distributor must be at cyl. 1.
4. Marks :
 on the flywheel must stand out for marking.
 on the cam wheel must match the marks on the mounting plate.
5. Loosen belt tensioner.
6. Dismount timing belt.

1. Turn the engine clockwise to the marks.

2. Marks on the crankshaft pulley / vibration damper must match the marks on the timing belt cover.
3. Rotor in the distributor must be at cyl. 1.
4. Marks :
 on the flywheel must stand out for marking.
 on the cam wheel must match the marks on the mounting plate.
5. Loosen belt tensioner.
6. Dismount timing belt.
 Tolerance Data 2009.2 Seat, Toledo 1,6i

Mounting 1

1. Control markings.
2. Fit the timing belt in the folowing order:
3. Crank pulley.
4. Water pump.
5. Cam wheel.
6. Tensioning wheel.
7. Mount :
 lower timing belt cover.
 crankshaft pulley / vibration damper.

1. Control markings.
2. Fit the timing belt in the folowing order:
3. Crank pulley.
4. Water pump.
5. Cam wheel.
6. Tensioning wheel.
7. Mount :
 lower timing belt cover.
 crankshaft pulley / vibration damper.
 Tolerance Data 2009.2 Seat, Toledo 1,6i

Mounting 2

1. For models with semi-automatic belt tensioners.

2. Tighten :
 belt tensioner counter clockwise past marking, so belt is 10 mm overtensioned.
 belt tensioner clockwise with Allen key until pointer aligns with the small notch and tighten bolt.
3. Turn crankshaft 720°.
4. Control :
 markings.
 belt tension, pointer must be parallel with sides.
5. ---------------------------------------
6. ---------------------------------------
7. For models with hydraulic tensioning elements:
8. Turn belt tensioner clockwise.
9. Inner stamp must be moved fully out.
10. The outer piston must rise approx. 1 mm
11. Tighten belt tensioner.
12. Turn crankshaft 720°.
13. Control markings.
14. A must be flush with the top of the outer stamp.
15. Distance "B" must be 25 - 29 mm.
16. The remainder is assembled in opposite order.

1. For models with semi-automatic belt tensioners.

2. Tighten :
 belt tensioner counter clockwise past marking, so belt is 10 mm overtensioned.
 belt tensioner clockwise with Allen key until pointer aligns with the small notch and tighten bolt.
3. Turn crankshaft 720°.
4. Control :
 markings.
 belt tension, pointer must be parallel with sides.
5. ---------------------------------------
6. ---------------------------------------
7. For models with hydraulic tensioning elements:
8. Turn belt tensioner clockwise.
9. Inner stamp must be moved fully out.
10. The outer piston must rise approx. 1 mm
11. Tighten belt tensioner.
12. Turn crankshaft 720°.
13. Control markings.
14. A must be flush with the top of the outer stamp.
15. Distance "B" must be 25 - 29 mm.
16. The remainder is assembled in opposite order.
 Fault-codes
Model: Toledo 1,6i Motor: AFT / Simos 09.1997 -

Faultcode Possible cause(s)

00000, - No stored faults!!,
00263, Transmission control Signal, Wires, Short-circuited to ground, ECU,
module
00268, Throttle valve position Wires, Sensor / Actuator defective,
module
00281, Vehicle speed sensor Fault in circuit,
00282, Throttle valve position Fault in circuit,
module
00305, Fuel check Wrong signal, Instrument cluster, Wires,
00513, Inductive crankshaft Signal,
position sensor
00514, Inductive camshaft Fault in circuit,
position sensor
00515, Hall sensor Fault in circuit,
00516, Idle switch Fault in circuit,
00517, Full throttle switch Fault in circuit,
00518, Throttle valve Signal,
potentiometer
00519, MAP/ MAF Faulty vacuum signal,
00520, MAF sensor Fault in circuit,
00521, CO potentiometer Fault in circuit,
00522, Coolant temperature Fault in circuit,
sensor
00523, Air temperature sensor Fault in circuit,
00524, Knock sensor 1 Missing signal,
00525, O2 sensor Fault in circuit,
00526, Speed pilot Brake pedal switch, Wires, Switch,
00527, Induction air Wires, Circuitry error, Sensor / Actuator defective,
temperature sensor
00528, Altitude sensor Fault in circuit,
00529, Crankshaft position Wires, Sensor / Actuator defective,
sensor
00530, Position sensor Idling adjuster, Sensor / Actuator defective, Wires/ connector,
Connector incorrectly joined,
00531, MAF sensor Reference voltage wrong,
00532, Voltage supply Fault in circuit,
00533, Throttle valve position Fault in circuit,
module
00534, Engine oil temperature Wires, Sensor / Actuator defective,
sensor
00535, Knock sensor 1 Fault in circuit,
00536, Knock sensor 2 Fault in circuit,
00537, O2 sensor Wrong mixture,
00539, Fuel temperature sensor Wires, Sensor / Actuator defective,
00540, Knock sensor 2 Missing signal,
00543, Inductive crankshaft Engine speed above maximum rpm,
position sensor
00544, Charge-pressure sensor Pressure too high,
00546, Data link Fault in circuit,
00549, Throttle valve Wrong signal, Short-circuited to ground, Wires,
potentiometer
00553, MAF sensor Fault in circuit,
00555, O2 sensor with Heater, Wires,
 Fault-codes
Model: Toledo 1,6i Motor: AFT / Simos 09.1997 -

Faultcode Possible cause(s)

pre-heater
00558, O2 sensor Mixture too lean,
00559, O2 sensor Mixture too rich,
00560, EGR temperature sensor Fault in circuit, Switch,
00561, System Fault in circuit, Mixture ratio too rich, Mixture ratio too lean,
00575, MAP/ MAF Fault in circuit,
00577, Knock control system Cyl. 1,
00578, Knock control system Cyl. 2,
00579, Knock control system Cyl. 3,
00580, Knock control system Cyl. 4,
00581, Knock control system Cyl. 5,
00582, Knock control system Cyl. 6,
00585, EGR temperature sensor Fault in circuit,
00586, Exhaust gas System,
recirculation
00609, Ignition module Primary circuit 1,
00610, Ignition module Primary circuit 2,
00611, Ignition module Primary circuit 3,
00624, A/C Fault in circuit,
00625, Vehicle speed sensor Signal,
00635, Heated lambda Heater,
00640, Heated lambda Relay control circuit electrical,
00670, Position sensor Idling adjuster,
00689, Air temperature sensor External,
00750, ECU lamp Fault in circuit,
01025, ECU lamp Fault in circuit,
01087, Default setting, Not ready,
01088, System Regulation,
01119, Transmission fluid Wrong signal,
01120, Camshaft position Incorrctly adjusted,
sensor A
01121, Camshaft position Incorrctly adjusted,
sensor B
01165, Throttle valve position Fault in circuit,
module
01182, Throttle flap sensor A/ Regulation,
Accelerator pedal position
01235, Secondary air injection Solenoid valve, Defective,
system
01242, ECU Wires,
01243, Canister purge valve Fault in circuit,
01244, O2 sensor Fault in circuit,
01247, Canister purge valve Wires,
01249, Cylinder 1 injector Fault in circuit,
01250, Cylinder 2 injector Fault in circuit,
01251, Cylinder 3 injector Fault in circuit,
01252, Cylinder 4 injector Fault in circuit,
01253, Cylinder 5 injector Fault in circuit,
01254, Cylinder 6 injector Fault in circuit,
01257, Idle control valve Wires,
01259, Fuel pump Relay control circuit electrical, Wires,
01262, Turbo/ Supercharger Fault in circuit,
 Fault-codes
Model: Toledo 1,6i Motor: AFT / Simos 09.1997 -

Faultcode Possible cause(s)

bypass valve
01264, Secondary air pump Fault in circuit,
01265, EGR valve Wires,
16486, MAF sensor Circuit low input,
16487, MAF sensor Circuit high input,
16496, Induction air Circuit low input,
temperature sensor
16497, Induction air Circuit high input,
temperature sensor
16500, Coolant temperature Circuit range/ performance,
sensor
16501, Coolant temperature Circuit low input,
sensor
16502, Coolant temperature Circuit high input,
sensor
16503, Coolant temperature Circuit intermittent,
sensor
16504, Throttle flap sensor A/ Fault in circuit,
Accelerator pedal position
16505, Throttle flap sensor A/ Circuit range/ performance,
Accelerator pedal position
16506, Throttle flap sensor A/ Circuit low input,
Accelerator pedal position
16507, Throttle flap sensor A/ Circuit high input,
Accelerator pedal position
16514, Heated lambda (Bank 1, Sensor 1),
16515, Heated lambda (Bank 1, Sensor 1),
16516, Heated lambda (Bank 1, Sensor 1),
16518, Heated lambda Slow response (Bank 1, Sensor 1),
16519, Heated lambda Heater control circuit (Bank 1 Sensor 1),
16534, Heated lambda (Bank 2, Sensor 1),
16536, Heated lambda Circuit/ open,
16537, Heated lambda Circuit/ open,
16538, Heated lambda Circuit/ open,
16554, Fuel trim Bank 1,
16555, System Too lean (Bank 1),
16556, System Fault in circuit,
16557, Fuel trim Bank 2,
16558, System Too lean (Bank 2),
16559, System Too Rich (Bank 2),
16684, Random Misfire detected,
16685, Cylinder 1 Misfire etected,
16686, Cylinder 2 Misfire etected,
16687, Cylinder 3 Misfire etected,
16688, Cylinder 4 Misfire etected,
16689, Cylinder 5 Misfire etected,
16690, Cylinder 6 Misfire etected,
16691, Cylinder 7 Misfire etected,
16692, Cylinder 8 Misfire etected,
16706, Ignition/ Distributor Missing signal,
engine speed input
16711, Knock sensor 1 Circuit low input (Bank 1),
16716, Knock sensor 2 Circuit low input (Bank 2),
 Fault-codes
Model: Toledo 1,6i Motor: AFT / Simos 09.1997 -

Faultcode Possible cause(s)

16721, Crankshaft position Circuit low input,
sensor A
16725, Camshaft position Circuit range/ performance (Bank 1),
sensor A
16784, Exhaust gas Flow,
recirculation
16785, Exhaust gas Flow insufficient detected,
recirculation
16786, Exhaust gas Flow excessive detected,
recirculation
16795, Secondary air injection Malfunction,
17509, O2 sensor Wires,
17514, O2 sensor Wires,
17540, O2 sensor Wires,
17541, O2 sensor Wires,
17609, Cylinder 1 injector Wires,
17610, Cylinder 2 injector Wires,
17611, Cylinder 3 injector Wires,
17612, Cylinder 4 injector Wires,
17613, Cylinder 5 injector Wires,
17614, Cylinder 6 injector Wires,
17621, Cylinder 1 injector Short circuit to plus, Wires,
17622, Cylinder 2 injector Short circuit to plus, Wires,
17623, Cylinder 3 injector Short circuit to plus, Wires,
17624, Cylinder 4 injector Short circuit to plus, Wires,
17625, Cylinder 5 injector Short circuit to plus, Wires,
17626, Cylinder 6 injector Short circuit to plus, Wires,
17733, Knock control system Cyl. 1,
17734, Knock control system Cyl. 2,
17735, Knock control system Cyl. 3,
17736, Knock control system Cyl. 4,
17737, Knock control system Cyl. 5,
17738, Knock control system Cyl. 6,
17747, Ignition/ Distributor Fault in circuit,
engine speed input
17749, Ignition coil A primary/ Short circuit to ground,
secondary
17751, Ignition coil B primary/ Short circuit to ground,
secondary
17753, Ignition coil C primary/ Short circuit to ground,
secondary
17799, Camshaft position Short circuit to ground,
sensor
17800, Camshaft position Short circuit to plus,
sensor
17801, Ignition coil A primary/ Signal,
secondary
17802, Ignition coil B primary/ Signal,
secondary
17803, Ignition coil C primary/ Signal,
secondary
17808, EGR valve Wires,
17809, EGR valve Short circuit to ground, Wires,
 Fault-codes
Model: Toledo 1,6i Motor: AFT / Simos 09.1997 -

Faultcode Possible cause(s)

17810, EGR valve Short circuit to plus, Wires,
17815, EGR temperature sensor Low input,
17816, EGR temperature sensor High Input,
17817, Canister purge valve Signal, Wires,
17818, Canister purge valve Short circuit to plus, Wires,
17908, Fuel pump Relay control circuit electrical, Wires,
17910, Fuel pump Short circuit to plus, Relay,
17912, Intake air Leak detected,
17913, Closed throttle position Circuit disconnected/ short circuited, Wires,
switch
17914, Closed throttle position Short circuit to ground, Wires,
switch
17915, Idle control valve Default setting,
17916, Idle control valve Default setting,
17917, Idle control valve Wires,
17918, Idle control valve Short circuit to plus,
17919, Intake valve Wires,
17920, Intake valve Short circuit to plus, Wires,
17966, Throttle valve position Wires,
module
17978, Immobilizer Key, KAM (Keep Alive Memory) error,
18008, Voltage supply KL15,
18010, Battery KL30,
18020, ECU ROM error,
65535, ECU Defective,
Diagnostic connector Flash code:
 Technical data on the vehicle
Make Seat Date: 26-07-2011
Model Toledo 1,6i Owner
Year 1998-1999 Registration No.
Engine AFT VIN
Variant 1. Reg. Date

Technical item Data

Engine
Engine ID code AFT
Number of cylinders R4
Number of valves 8, OHC
Capacity/ (bore/ stroke) 1595 cm³ (81,0/ 77,4)
Compression ratio (RON) 10.3: 1 (95 unleaded)
Max. output kW (din hp)/ rpm 74 (101)/ 5800
Max. torque NM/ rpm 140/ 3500
Engine code location Engine block front side
Vehicle Identification Number location Firewall
Vehicle identification plate location Right inner wing
Production year code in VIN 10th digit, model yr, W = 1998, X = 1999 i
Valve clearance, inlet (cold/ hot) (Hydraulic)
Valve clearance, exhaust (cold/ hot) (Hydraulic)
Valve angle/ seat angle / 45°
Compression pressure, bar 10.0 - 15.0 (Min. 7.5) Max. difference 3.0
Oil pressure/ rpm, bar Min. 2.0/ 2000 (80°C)
Radiator cap, bar/ thermostat °C 1.4 - 1.6/ 87° C i
Clutch freeplay, mm Self-adjusting
Repair time: Clutch renewal 3 hours
Timing belt: Inspection 30,000 km
Timing belt: Renewal interval 120,000 km/ 4 years
Repair time: Timing belt renewal 48 minutes
Drive belt i
Engine management
Engine management system Siemens Simos
Spark plug NGK 8 BKUR 6 ET - 10
Electrode gap, mm 0,70 - 0,90
Firing order 1 - 3 - 4 - 2 (Cylinder 1 at timing gear) i
Ignition timing (BTDC) i
Diagnostic connector Dashboard left side i
Timing mark location Belt pulley
Ignition coil: Primary/ secondary resistance 0,5 - 1,5 ohm/ 2,5 - 4,0 kohm i
Fuel pressure, w/wo vacuum, bar 2.5/ 3.0 (775 cm³/ 30 sec.)
Holding pressure, bar 2.0 after 10 minutes
Injector resistance, ohm 15,0 - 20,0
Min. idle manifold vacuum, mbar 590
Coolant temperature sensor 20°/ 80°C / 0,2 - 0,3 kohm
Intake air temperature sensor 20°/ 80°C 1,50 kohm/ 0,30 - 0,49 kohm
Cylinder balance permitted (maximum duration) No
Electrical system
Battery 12 V 63 Ah
Starter motor current (cranking), A 12 V/ 175 A
Voltage relay, Volt at/ amp. 12,5 - 14,5 V/
Terminal definitions DIN 72 552
Alternator max, A 12 V/ 70 A
Wheel alignment
Load Unloaded
 Technical item Data

Wheel alignment
Toe-in, ° 0° 00' ± 10'
Camber° ÷ 0° 25' ± 20' i
Caster° 1° 40' ± 30' i
Toe-out on turns, inner wheel° 20°
Toe-out on turns, outer wheel° 18° 40' ± 30'
Rear camber° ÷ 1° 30' ± 30' i
Rear toe-in ° 0° 20' ± 10' i
Tyre size 175/ 70 R 13
Tyre pressure, front/ rear, bar 2,0 - 2,2/ 2,1 - 2,6
Free play in suspension parts Factory data i
Tightening torques
Tightening, NM Torque standards
Cylinder head bolts, stage 1, Nm 40 Nm new oiled i
Cylinder head bolts, stage 2, Nm 60 Nm
Cylinder head bolts, stage 3, Nm + 90°
Cylinder head bolts, stage 4, Nm + 90°
Cylinder head bolts, stage 5, Nm (No retightening)
Repair time: Cylinder head gasket 2 hours and 30 minutes
Main bearings, Nm 65 Nm + 90° oiled
Connection rod bearings, Nm 30 Nm + 90°
Flywheel, Nm 60 Nm + 90°
Crankshaft pulley/ vibration damp. Nm 45/ (Timing belt pulley 90 Nm + 90°)
Camshaft pulley/ bearings, Nm 80/ 20
Timing belt tensioner, Nm 45'
Spark plugs, Nm 30
Wheel nuts/ bolts, Nm 110
Wheel hub, front/ rear, Nm 265/
Repair time: Renew one rear wheel bearing 48 minutes
Repair time: Renew one front wheel bearing 1 hour and 25 minutes
Brakes
Front, min. thickness (new) 10.0 mm (12.0 mm)
Rear, min. thickness (new) 201,5 mm (200,0 mm)
Repair time: Front brake disc renewal (2 pc.) 1 hour
Repair time: Rear brake drum renewal (2 pc.) 1 hour and 15 minutes
Capacities
Engine oil/ - incl. filter, litre 3,5/ 4,0 (APi. SF - SG)
Manual transmission, litre 2.0 (APi. GL-4 SAE 80)
Power steering, litre (VW: G 002 000)
Cooling system, litre 5.5
A/C fluid, type/ gram R134a/ 850 ± 30
A/C oil, type/ cm³ / 115 - 130
Environmental parametres
Idle speed, rpm 790 - 890
CO% at idle speed Max. 0,5 i
CO% at Increased idle speed Max. 0.3
Lambda 1,00 ± 0,03

Remarks

n Order No.:
n Mechanic
nn
Seat Toledo 1,6i
Diagnostic connector

Diagnostic connector

Pic. 1
Seat Toledo 1,6i
Tightening, NM

Tightening torques
M4              8.8                2.4 Nm
M4            10.9                3.6 Nm
M5              8.8                5.0 Nm
M5            10.9                7.3 Nm
M5            12.9                8.0 Nm
M6             8.8                 8.6 Nm
M6            10.9              12.6 Nm
M6            12.9              14.0 Nm
M7              8.8              14.0 Nm
M7            10.9              20.5 Nm
M7            12.9              22.5 Nm
M8              8.8              20.5 Nm
M8            10.9              30.5 Nm
M8            12.9              33.5 Nm
M8x1          8.8                 22 Nm
M8x1        10.9                 32 Nm
M8x1        12.9              35.5 Nm
M10            8.8                 41 Nm
M10          10.9                 60 Nm
M10          12.9                 66 Nm
M10x1        8.8                 44 Nm
M10x1      10.9                 65 Nm
M10x1      12.9                 72 Nm
M12            8.8                 71 Nm
M12          10.9               104 Nm
M12          12.9               116 Nm
M12x1.5     8.8                 73 Nm
M12x1.5   10.9               108 Nm
M12x1.5   12.9               120 Nm
M14            8.8               112 Nm
M14          10.9               165 Nm
M14          12.9               185 Nm
M14x1.5     8.8               120 Nm
M14x1.5   10.9               175 Nm
M14x1.5   12.9               195 Nm
M16            8.8               175 Nm
M16          10.9               255 Nm
M16          12.9               280 Nm
M16x1.5     8.8               180 Nm
M16x1.5   10.9               265 Nm
M16x1.5   12.9               295 Nm
M18           8.8                240 Nm
M18          10.9               355 Nm
M18          12.9               395 Nm
M18x1.5     8.8               265 Nm
M18x1.5   10.9               385 Nm
M18x1.5   12.9               430 Nm 
Pic. 1
Seat Toledo 1,6i
Cylinder head bolts, stage 1, Nm

Tightening sequence

Pic. 1