SEAT Workshop Service and Repair Manuals

Removing engine Special tools and workshop equipment required

t  Workshop hoist -VAS 6100-

t  Lifting tackle -3033-   Note t  Read out radio anti-theft code as the battery earth strap has to be disconnected during the next work steps. t  The engine is removed forwards together with the gearbox. t  All the cables, that are opened or cut during dismounting, should be placed again in the same location previously occupied during the fitting.   WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route lines of any kind so that the original routing can be restored. t  Ensure that there is sufficient clearance to all moving or hot components. –  With ignition switched off, disconnect earth strap from battery. → Electrical system; Rep. gr.27. –  Dismount the air filter housing together with the air mass meter and the connecting pipe → Chapter. –  Remove battery → Electrical system; Rep. gr.27.

–  Remove battery carrier, unscrew securing bolts -arrows- for this. –  Remove engine cover panel → Chapter. –  Remove fuel filter → Chapter. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Drain coolant → Chapter. –  Extract air conditioning refrigerant → Heating, air conditioning; Rep. gr.87. –  Remove lock carrier → General body repairs, exterior; Rep. gr.50.

–  Open clips -arrows- and pull coolant hoses off coolant expansion tank.

–  Pull off vacuum hoses -1- and -2- for charge air control.

–  Separate connectors for exhaust temperature sender 1 -G235--1-, for Lambda probe -G39--3- and for exhaust temperature sender 3 -G495--2- and exhaust temperature sender 4 -G648--4-. –  Cut cable ties of cables. –  Remove the line from the bracket on the front side of the plenum chamber and from the exhaust gas turbocharger.

–  Pull vacuum connection -A- off vacuum pump and detach vacuum hose -arrow-.

–  Remove refrigerant line securing bolt -arrow- from air conditioner compressor. –  Separate refrigerant line at air conditioner compressor and lay it to side without kinking.

–  Disconnect quick-release couplings for heat exchanger -arrows- on plenum chamber bulkhead.

–  Unbolt positive cable -arrow- from starter at central electrics and lay cable on engine. Vehicles with dual clutch gearbox. –  Remove shift mechanism from gearbox → 6-speed dual clutch gearbox; Rep. gr.30.

–  To release, turn catch of mechatronic connector -arrow- and pull connector off. Vehicles with manual gearbox. –  Disconnect selector mechanism from gearbox → 6-speed manual gearbox; Rep. gr.30. –  Remove pipe/hose assembly or plastic line from clutch slave cylinder → 6-speed manual gearbox; Rep. gr.30. All other vehicles continued –  Remove wiper arms and plenum chamber cover → Electrical system; Rep. gr.92. –  Remove plenum chamber bulkhead → General body repairs; Rep. gr.50. –  Remove engine control unit from retainer → Chapter.

–  Release connector for engine wiring harness -arrow- and pull off from engine control unit.

–  Disconnect connectors -1- and -2- on left longitudinal member. –  Unscrew earth wire on gearbox. –  Open locking mechanism -A- of feed-through in plenum chamber bulkhead.

–  Pull out upper part upwards and remove engine wiring harness from cable guide. –  Disconnect all connectors between starter, gearbox and body.

–  Unscrew securing bolt -arrow- on upper bracket for particulate filter and loosen securing bolt of bracket on cylinder head one turn.

–  Open quick-release fasteners -A- and -B- of fuel lines and pull fuel lines off.

–  Detach connector -1- from pressure differential sender -G505-, undo bolts -arrow-. –  Remove fuel filter and pressure differential sender -G505- and place on engine. –  Disconnect connector on oil level and oil temperature sender -G266- at oil sump. –  Remove drive shafts → Running gear, axles, steering; Rep. gr.40.

–  Unscrew bolts -1…3- and remove pendulum support. Vehicles with auxiliary heater

–  Open clips -arrows- and pull coolant hoses off auxiliary heater coolant. All other vehicles continued

–  Loosen securing clamp -1- between particulate filter and turbocharger. –  Unscrew securing nuts above particulate filter bracket using ratchet wrench -T10384-.

–  Unscrew securing nuts -arrows- of particulate filter bracket -A- on crankcase and remove bracket. –  Push particulate filter aside and fix it in position on plenum chamber bulkhead using suitable means.   Note Check that all hose and line connections between engine, gearbox and body have been detached.

–  Attach lifting tackle -3033- as follows and take up weight of »engine/gearbox assembly« in installation position using workshop crane -VAS 6100-. Vibration damper end: l  Position 2. Flywheel end: l  Position 8.

–  Unscrew securing bolts -arrows- of assembly mounting on engine.

–  Unscrew securing bolts -arrows- of assembly mounting on gearbox.   Note Carefully guide »engine/gearbox assembly« when removing to avoid damage to body. –  Lower »engine/gearbox assembly« slightly and remove forwards. Secure engine to engine and gearbox support -VAS 6095- to carry out repairs → Chapter.