SEAT Workshop Service and Repair Manuals

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

Work sequence

• ‒ The engine is removed downwards together with the gearbox.
• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• ‒ → Remove air guide trim -1-.
• ‒ Remove battery trim -2-.

• ‒ Remove battery.

=> Electrical system; Repair group 27; Battery; Removing and installing battery

• ‒ → Unbolt -arrows- battery trim with coolant expansion tank and lay to side, do not open coolant system.
• ‒ Remove ribbed belt .
• ‒ Disconnect intake hose from throttle valve control part.

=> Repair group 24; Motronic injection and ignition system; Servicing injection part

• ‒ Remove spark plug connectors with tool 3277 A and unclip ignition cables:

=> Repair group 28; Motronic injection and ignition system; Servicing ignition part

• ‒ → Remove H.T. cable guides -1-, -2- and -4-.
• ‒ Remove cover above intake manifold upper part -3-.
• ‒ Detach throttle cable and support bracket at throttle valve control part (do not remove retainer).
• ‒ Unclip fuel pipes on cylinder head cover.
• ‒ Mark fuel pipes and pull off fuel manifold.

• ‒ Separate 42-pin connector (near ignition transformer).
• ‒ Pull vacuum hose off brake servo.
• ‒ Unbolt P.A.S. hydraulic pipes from engine support.

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes

• ‒ Remove power assisted steering vane pump with bracket and secure to body with wire; hoses remain connected.

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and installing vane pump on vehicles with VR6 engine

• ‒ Remove front exhaust pipe => Page 26-2, exhaust manifold, front exhaust pipe and catalyst with attachments.
• ‒ Remove secondary air pump fan ring with fan and motor => Page 19-17, Removing and installing fan and radiator
• ‒ Disconnect all electric wires from gearbox, alternator and starter and move clear.
• ‒ Disconnect all coolant, vacuum and breather hoses from engine.

Vehicles with manual gearbox

• ‒ Lever off pipe/hose from slave cylinder on gearbox:

=> 5-Speed manual gearbox 006; Repair group 30; Assembly overview; Hydraulics and clutch release mechanism

• ‒ Remove operating cable from gearbox:

=> 5-speed manual gearbox 006; Repair group 34; Servicing selector mechanism; Removing and installing operating cables

• ‒ Remove drive shafts:

=> Running gear; Repair group 40; Servicing drive shafts; Removing and installing drive shafts.

Vehicles with automatic gearbox

• ‒ Remove selector lever cable from gearbox:

=> Automatic gearbox 099; Repair group 37; Servicing selector mechanism; Dismantling and assembling selector mechanism

• ‒ Unbolt drive shafts from gearbox flange shaft and tie up.

=> Running gear; Repair group 40; Servicing drive shafts; Removing and installing drive shafts.

Vehicles with air conditioner

• ‒ Observe additional information and removal instructions => Page 10-16.

Continuation for all vehicles

• ‒ Fit engine support 3395 onto engine/gearbox jack V.A.G 1383 A .

• ‒ → Fit engine support 3395 onto cylinder block and tighten securing nuts -1- to
  40 Nm.
• ‒ Remove pendulum support.

=> Running gear; Repair group 40; Servicing front wheel mounting; I - Assembly overview, assembly carrier, anti-roll bar, wishbone

• ‒ → Unbolt assembly mounting, right securing bolts -1-.

• ‒ → Unbolt assembly mounting, left securing bolts -A-.
• ‒ Lower assembly carefully.

Note:

The assembly must be carefully guided when lowering, to prevent damage to the bodywork.