SEAT Workshop Service and Repair Manuals

Dismantling: notes –  The engine is removed downwards together with the gearbox.   Caution When doing any repair work, especially in the engine compartment, due to the cramped conditions, pay attention to the following: Route all sorts of pipes (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring so that the original positions are restored on reassembly. Ensure sufficient clearance from all moving or hot components. –  All cable ties which are opened or cut open when removing engine, must be replaced in the same position when re-installing.

–  Remove engine cover in the -direction of the arrow- .   Note! To carry out this work it will be necessary to disconnect battery earth strap. The vehicle should be checked for a fitted radio. If necessary obtain radio anti-theft code first. –  With the ignition switched off disconnect battery earth strap. –  Open the expansion tank sealing cap to release pressure in cooling system.

–  Remove battery and battery retainer. → Rep. Gr.27 –  Remove the flexible hose which connects the air filter to the intake hose. –  Remove air cleaner → Fig..

–  Remove lower engine protection: → General body repairs-assembly work; Rep. Gr.50 –  Remove right-hand drive shaft and disconnect left-hand drive shaft at gearbox: → Running gear, axles, steering; Rep. Gr.40 –  Raise the articulated left-hand driveshaft and secure the driveshaft to the roll bar. –  Remove the front exhaust along with the catalytic converter → Chapter, Exhaust system: dismantling and assembling –  Drain coolant → Chapter –  Remove coolant hoses from engine using assembly tool for springtype clamps -T20029-.

–  Remove lower coolant hose from radiator -arrow-.

–  Furthermore, the front coolant hose should be removed from the oil radiator -arrow- and the rest of the coolant emptied. –  Disconnect all electric wires from gearbox, compressor, alternator and starter and leave to one side. –  Remove interconnecting, coolant, vacuum and intake hoses on engine. –  Remove hydraulic clutch slave cylinder: removal → 5-speed manual gearbox 02T; Rep. Gr.30 –  Disconnect selector mechanism from gearbox: → 5-speed manual gearbox 02T; Rep. Gr.34   Caution The fuel and the pipes may be very hot (danger of burns) Fuel system is under pressure. Before opening the system, place a cloth around the connection and depressurise, releasing with care. Use protective glasses and gloves for all fuel system assembly work!

–  Uncouple fuel feed and return pipes-arrows- from the injector pump. –  Seal the pipes so that the fuel system is not contaminated by dirt etc. –  Observe rules for cleanliness → Chapter. –  Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.

–  Unbolt pendulum support -arrows-.