SEAT Workshop Service and Repair Manuals

Notes on removing –  The engine is removed downwards together with the gearbox. –  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. –  Remove engine cover. –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. –  With ignition switched off, disconnect earth strap from battery. –  Remove battery.

–  Remove trim panel/air duct -1-. –  Unbolt battery trim panel -2- with coolant expansion tank and lay aside; do not yet open cooling system.

–  During remaining disassembly, disconnect connectors -arrows- behind battery. –  Remove battery bracket. –  Pull off or disconnect all other electrical cables as necessary from engine and body and expose. –  Remove air cleaner → Rep. Gr.24 Vehicles with engine code AJH –  Remove intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH.

–  Disconnect throttle cable at throttle valve control module cable disc and support bracket -arrows- (do not remove locating clip on support bracket). Vehicles with engine code AWC –  Remove intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AWC. Continuation for all vehicles

–  Disconnect fuel supply and return pipe and cable from activated charcoal filter system solenoid valve 1 -arrows- from fuel rail.   Caution Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. –  Unclip fuel hoses from bracket. –  Seal lines so that fuel system is not contaminated by dirt. –  Observe rules for cleanliness → Chapter. –  Pull off necessary vacuum and breather hoses from engine. –  Remove noise insulation tray. Vehicles with engine code AJH –  Remove pressure hose between secondary air pump motor and combination valve → Chapter, Removing and installing parts of the secondary air system.   Note! Press buttons on hose couplings to do this. –  Remove air pipes between turbocharger/charge air cooler and charge air cooler/throttle valve control module → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH. Vehicles with engine code AWC –  Remove pressure hose between secondary air pump motor and combination valve → Chapter, Removing and installing parts of the secondary air system.   Note! Press buttons on hose couplings to do this. –  Remove air pipes between turbocharger/charge air cooler, turbocharger/air filter and charge air cooler/throttle valve control module → Chapter, Removing and installing parts of the charge air cooling system: engine code AWC. Vehicles with 5-speed manual gearbox 006 –  Pull pipe/hose off slave cylinder on gearbox → Rep. Gr.30 –  Remove operating cables from gearbox → Rep. Gr.34 –  Remove drive shafts → Rep. Gr.40 Vehicles with 6-speed manual gearbox 02N –  Pull pipe/hose off slave cylinder on gearbox and expose → Rep. Gr.30 –  Remove operating cables from gearbox → Rep. Gr.34 –  Remove drive shafts → Rep. Gr.40 Vehicles with 4-speed automatic gearbox 099 –  Remove selector lever cable from gearbox → Rep. Gr.37 –  Unbolt drive shafts from flanged shaft/gearbox and tie up → Rep. Gr.40 Vehicles with 5-speed automatic gearbox 09B –  Remove selector lever cable from gearbox → Rep. Gr.37 –  Unbolt drive shafts from flanged shaft/gearbox and tie up → Rep. Gr.40 Vehicles with air conditioner –  Observe additional remarks and installation work → Chapter. Continuation for all vehicles –  Remove poly-V-belt → Chapter. –  Unbolt power assisted steering vane pump from compact bracket and lay to side, hoses remain connected: → Rep. Gr.48. –  Unbolt hydraulic line for power assisted steering from right engine bracket. –  Remove front exhaust pipe → Chapter, Front exhaust pipe and catalytic converter and attachments. –  Drain coolant → Chapter. –  Pull connectors off thermo switch and radiator fan. –  Pull radiator coolant hoses off engine using hose clip pliers -V.A.G 1921- or spring-type clip pliers -VAS 5024A-. –  Remove front bumper → Rep. Gr.63 –  Bring lock carrier into service position → Rep. Gr.50 –  Insert engine bracket -T10012- in engine and gearbox jack -V.A.G 1383 A-.

–  Bolt engine bracket -T10012- to cylinder block with securing bolt M10x25. Torque setting: 45 Nm. –  Lift engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A-. –  Remove pendulum support → Rep. Gr.40

–  Unscrew right assembly mounting securing bolts -1-. Vehicles with engine code AJH

–  Unscrew left assembly mounting securing bolts -A-.   Note! To remove securing bolts, use stepladder V.A.S -VAS 5085-. –  Carefully lower assembly slightly.

–  Unscrew securing bolts -A- and remove bracket -B-. Vehicles with engine code AWC

–  Unscrew left assembly mounting securing bolts/nuts -arrows-.   Note! To remove securing bolts, use stepladder V.A.S -VAS 5085-. Continuation for all vehicles –  Carefully lower engine with gearbox.   Note! Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork, hoses and lines.