SEAT Workshop Service and Repair Manuals

Removing engine   Note t  Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. t  The engine is removed forwards together with the gearbox and with mounted particle filter.. t  So that the steering wheel is not locked, keep the key in the ignition. t  The front wheels should be removed before proceeding with the removal of the engine assembly. In this way, the vehicle may be lowered using the platform until the protection plates for the disk brakes are almost touching the ground. Thus, the most ergonomic working position is achieved for reaching the components in the engine compartment. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. t  Some components can not be removed, or only with a great deal of difficulty, while the engine is mounted. All of the faulty or damaged components should be identified before removal and should be replaced before re-installing the engine. t  After removing coolant or fuel lines, these must be sealed using the engine sealing plug set -VAS 6122- to prevent dirt from entering or coolant or fuel from running out.   WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, active carbon filter system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring so that the original positions are restored. t  Ensure that there is sufficient clearance to all moving or hot components. Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Lifting tackle -3033-, see equivalent → Anchor

t	Hose clamp -3094-, see equivalent → Anchor

t	counterhold -T10038-, see equivalent → Anchor

t	counterhold -T10404-, see equivalent → Anchor

t	Workshop crane -VAS 6100-, see equivalent → Anchor

t	Engine sealing plug set -VAS 6122-, see equivalent → Anchor

Removing –  Before removing the error memory, call-up all control units → Vehicle diagnostic, testing and information system VAS 5051. –  With the ignition switched off, disconnect battery earth strap → Electrical system; Rep. gr.27. –  Remove charge air cooler → Chapter. –  Completely dismantle and remove the lock carrier plate → Bodywork, exterior fitting work; Rep. gr.50

–  Undo bolt -1- and lay the filling pipe with fill neck-2- of the washer fluid reservoir free.   Note Disregard: -Pos. 3-. –  Remove poly V-belt → Chapter.

–  Disconnect electrical connection -1- for magnetic coupling on air conditioner compressor. –  Remove bolts -arrows- for air conditioner compressor.   WARNING The air conditioner refrigerant circuit must not be opened. To prevent damage to the air conditioning compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

–  Fit the guide pins -T10093- as shown in the figure and fit the air conditioner compressor. –  Fit the protective elements at those positions -arrows- so that damage is prevented to the bodywork and the coolant lines. –  Support the condenser using the support tool -T10038-, as shown in the figure.

–  Remove the electrical connector -1- from the air mass meter -G70-. –  Uncouple the flexible air hose -3- and the flexible air conduit -2-. –  Unscrew the bolt -4- and remove the air filter housing.

–  Disconnect the hoses -1- on the vent on the crankshaft case. Press in to release the retaining clips. –  Move vacuum hoses -arrows- on air pipe clear. –  Loosen hose clip -2- and detach air pipe. –  Turn back the flexible air conduction tube and detach it from the exhaust gas turbo compressor.

–  Remove the vacuum hose -2- of the underpressure capsule from the turbocharger. –  Separate vacuum hose -3-.   Note Disregard: -Pos. 1-.

–  Separate the pressure hose -arrow- in the servo-brake amplifier. –  Remove battery → Electrical system; Rep. gr.27.

–  Extract the bolts -arrows- and extract battery bracket.

Vehicles with manual gearbox –  Remove the securing elements for the control cables from the selection and relay rods.

–  Remove the control cable support from the gearbox and move to one side -arrows-.

–  Pinch off the pressure pipe to the clutch slave cylinder using a Pressure tool -3094-. –  Separate the pressure tube -1- from the hose connection; to do this, pull the securing clip -arrow- upwards.   Caution Do not depress clutch pedal after removing slave cylinder. Vehicles with direct shift gearbox –  Remove the drive cable of the selector lever from the gearbox and store to the side → Rep. gr.34. Vehicles with engine control unit without antitheft protection –  Remove engine control unit → Chapter. Vehicles with engine control unit with antitheft protection –  Remove engine control unit → Chapter. Continuation for all vehicles –  Release all low pressure hoses

–  Release the engine wiring harness guide -arrow- and pull out upwards.

–  Open the clips on the cable guide -arrows-.

–  Separate the electrical connector -1- from the support and detach it. –  Open the wiring guide lock found below. –  Unclip the engine wiring harness to the control unit from the wiring guide. –  Remove wiring harness from cable guide on longitudinal member and lay to side on engine.

–  Move both bolts in the direction indicated by the -arrow- and remove the electrical module cover (engine compartment).

–  Unscrew and expose the terminal 30 wire -arrow- in the electronics box (engine compartment).

Separate the following connections: 2 -  Exhaust gas temperature sender 4 -G648- 3 -  Exhaust gas temperature sender 1 -G235- 4 -  Lambda probe -G39- 5 -  Exhaust gas temperature sender 3 -G495-

–  Disconnect the connector -2-, undo the bolt -3- and remove the pressure sensor 1 of exhaust gases -G450- with bracket in the direction of the -arrow-.   Note Disregard -item 1-.

–  Remove the fuel hose -2- from the holder. –  Pull retainer for fuel lines off upwards -arrow- and lay to side. –  Disconnect electrical connection -1- on supplementary fuel pump -V393-. –  Unscrew the bolts -3- and remove the holder together with the supplementary fuel pump -V393- and place on the engine.

–  Disconnect from the dashboard the coolant hoses to the heating radiator -arrows-.

–  Unplug connector -2- of reverse gear light switch.

–  Unbolt earth wire -1-. –  Detach wires -2- and -3- from starter motor. –  Release the cables from the connections on the starter motor. –  Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side. –  Separate all connecting, vacuum and intake hoses from engine.

Front-wheel drive vehicles –  Unbolt heat shield for right drive shaft -arrows-.

Vehicles with four-wheel drive –  Unscrew the insulating panel for the right half shaft from its mounting at the angular gears -arrows-. –  Remove the cardan shaft → final group 0AV; Rep. gr.39. Continuation for all vehicles –  Remove the right-hand drive shaft → Rep. gr.40. –  Unbolt the left drive shaft from the gearbox flange.

–  Unscrew bolts -1 ... 3- and take pendulum support out.

–  Unscrew the bolts -arrow- and remove the heat plate -1- above the steering housing. –  Mount the support tool -T10404- onto the vibration damper of the front section of the exhaust pipe with particle filter.   Note The mounting on the front section of the exhaust pipe with particle filter should not be bent by more than 10° otherwise there is a risk of damage.

–  Unscrew securing nuts from the clamp -1-. In that case it is not necessary to unscrew nuts -arrows-.

–  Unscrew the suspension element -arrow- and remove the bracket of the exhaust pipe.

–  Hook the suspension device -3033- as described below and using the workshop crane -VAS 6100-, lift the »engine assembly/gearbox« into its assembly position. Vibration damper end: Position 2. Flywheel end: Position 8. –  Set the flywheel side lower than the V-belt / vibration damper side. Remove the respective spindle for this purpose.   Note Check that all hose and line connections between engine, gearbox and body have been detached.

–  Undo the bolts -A, B, C- and remove the engine console completely.

–  Unscrew bolts -1 and 2- and remove the engine bearing completely.

–  Unscrew the bolts-arrows- and remove the gearbox supports.   Note t  When removing the engine assembly, continue with care so that the bodywork is not damaged. t  The engine must be raised together with the removal of the engine to the front so that the hooks / supports of the particle filter do not obstruct the steering housing. t  Look through the right wheel housing to check if the hooks / supports of the particle filter do not obstruct the steering housing and if they have to be guided so that no damage is caused. –  Slightly lift »engine/gearbox assembly« and remove forwards.   Caution When it looks like the engine should remain removed for a longer period, align the lines of the air conditioning system tension free.