SEAT Workshop Service and Repair Manuals

Engine: dismounting

Special tools and workshop equipment required

t	Engine support -T40075 A- with adapters /4, /5, /6

t	Torque wrenches -V.A.G 1331-

t	Hydraulic column jack -V.A.G 1383 A-

t	Engine and gearbox support -VAS 6095-

t	Drip tray for workshop hoist -VAS 6208-

Note The engine support -T40075- can continue to be used if converted as described in the respective work sequence. Converting engine support -T40075-

–  Scribe dimensions -a- and -b- as shown. Dimension -a-: 24.5 mm Dimension -b-: 49.0 mm –  Mark position with a centre punch. –  Drill a hole with a 13.0 mm bit. –  Identify engine support with an -A- behind tool designation.

t	Hose clip pliers -VAS 6340-

t	Stepladder -VAS 5085-

t	Torque wrenches -V.A.G 1332-

t	Guide rods -T10093-

Note Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.

–  Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.

–  Unbolt heat shield over turbocharger -arrows-. –  Remove air filter → Chapter. –  Open and close expansion tank cap to release pressure in cooling system. –  Drain coolant → Chapter.   Note Pull coolant hoses off engine with hose clip pliers -VAS 6340-.

–  Pull coolant hoses -arrows- off coolant expansion tank.   WARNING Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. –  Disconnect the fuel supply line -1- and line from activated charcoal filter system solenoid valve 1 -N80--2- on the clutch.   Note Press in securing ring to release fuel and breather lines. –  Seal lines so that no dirt is able to enter fuel system. –  Observe rules for cleanliness → Chapter. –  Remove lower engine splash guard. –  Remove front left and right wheel housing liners → General body repairs; Rep. gr.66. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50. The engine is removed downwards together with the gearbox. –  Connect battery → Electrical system; Rep. gr.27 –  Remove battery and battery holder → Electrical system; Rep. gr.27. –  All the cable fixings that are opened or cut during removal of the cylinder head must be fitted in the same position when reinstalling the engine. –  Remove all of the electrical cables from the gearbox, alternator, and starter motor leaving them uncovered. –  Disconnect all other electrical connections as necessary from engine and lay to one side. –  Pull vacuum and breather flexible hoses off the engine. –  Remove plenum chamber bulkhead → General body repairs; Rep. gr.50. –  Remove engine control unit -J623- → Chapter.

–  Open all line guide fasteners -arrows-. –  Remove wiring from engine control unit. –  Secure lines/wiring to engine with a cable tie.

–  Remove wiring for Lambda probe after catalytic converter -G130- and for alternator from cable guides -arrows-. –  Disconnect connector for Lambda probe after catalytic converter -G130-.

–  Remove Lambda probe after catalytic converter -G130--1-. –  Open hose clip -3- and remove charge air pipe -2-. –  Unbolt exhaust pipe from catalytic converter -arrows-.

–  Loosen securing nuts of clamping sleeve -arrows- and slide it forwards on exhaust pipe -1-.

–  Unscrew nuts -arrows- and pull exhaust pipe backwards. –  Push exhaust pipe backwards out of mounting -1-. –  Remove exhaust pipe.

–  Disconnect pendulum support -arrows-. Vehicles with manual gearbox: –  Unbolt selector mechanism from gearbox → 6-speed manual gearbox 0BB; Rep. gr.34.

–  Remove hydraulic clutch slave cylinder hose -1-: → 6-speed manual gearbox 0BB; Rep. gr.30.   Caution Do not depress clutch pedal. Vehicles with dual clutch gearbox: –  Remove selector mechanism from gearbox → 6-speed dual clutch gearbox 02E; Rep. gr.34. Continuation for all vehicles: –  Remove Poly V-belt → Chapter. –  Remove air conditioner compressor → Heating, air conditioning system; Rep. gr.87.   Note The air conditioning system lines must not be opened. –  Attach the air conditioning compressor to the lock carrier plate. –  Ensure that lines are not kinked. –  Observe additional information and installation work → Chapter.

–  Disconnect coolant pipe -1- from the cylinder block. –  Remove right drive shaft, unscrew left drive shaft at gearbox and tie up → Running gear, axles, steering; Rep. gr.40

Engine support -T40075A- with adapters -/4-, -/5- and -/6- is required to lower engine with gearbox.

–  Screw adapter T40075A /4 into the crankcase to stop. –  Position engine support -T40075A- with adapters -/5- and -/6- on crankcase.

–  Secure engine support -T40075A- hand-tight to crankcase using bolt -1-.

–  Tighten all bolts on the engine support -T40075A- to 20 Nm. –  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383 A-.

–  Unbolt engine side of assembly mounting from above -arrows-.

–  Unbolt gearbox side of assembly mounting from above -arrows-.   Note t  To remove securing bolts use stepladder -VAS 5085-. t  When the assembly is lifted out, it must be carefully guided to prevent damage to bodywork. –  Carefully lower engine and gearbox.