SEAT Workshop Service and Repair Manuals

Removal:   Note Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain anti-theft coding if necessary. –  The engine is removed forwards together with the gearbox. –  With ignition switched off, disconnect battery earth strap. –  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 the air filter housing → Chapter.

–  Pull off connector -1- of gas mode control unit -J659-. –  Unscrew the bolts -arrows- and remove gas mode control unit -J659- from holder. –  Remove the battery and its support. –  Open and close coolant expansion tank cap to release pressure in cooling system. –  Disconnect all electrical wiring from gearbox, alternator and starter and push to one side.   WARNING There is a danger of injury due to escaping gas. The system is under pressure. Wear suitable protective measures, such as protective gloves and protective goggles. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

–  Slacken the clamp -arrow 2- and remove the gas hose. –  Unplug connector -3- from the gas distribution rail sensor -G401-. –  Pull connector -4- off the gas injectors.   Note Disregard item -1-. l  Gas hoses remain connected to gas rail.

–  Separate the connector -1- of the throttle valve module -J338- and the solenoid valve 1 for activated carbon filter -N80-. –  Loosen the wiring from the clip -arrow-. –  Disconnect the connector -2- from the intake manifold pressure sender -G71-.   Note Ignore positions -4 and 5-. –  Unplug connectors -3- from all injectors. –  Place the cable harness aside. –  Pull off or disconnect all other electrical connections as necessary from engine and push to one side.

–  Remove the solenoid valve 1 for activated carbon filter -N80--1- from the intake manifold -4-. –  Detach the depression hose -2-.   Note Disregard item -3-.   WARNING Fuel supply line is pressurised. Wear safety goggles and appropriate clothing to avoid injury and contact with skin. Before releasing the connections on the hoses, place absorbent cloths round the connection. Then eliminate the pressure by carefully separating the pipe.

–  Remove the fuel supply tube -1-.   Note t  Disregard item -2-. t  Press in safety ring to release fuel lines. –  Seal lines so that no dirt is able to enter fuel system. –  Observe rules for cleanliness → Chapter. –  Pull connectors off thermal switch and radiator fan. –  Remove engine splash guard. –  Disconnect front exhaust pipe from exhaust manifold → Chapter.

–  Unscrew and remove the bolts -arrows- of the pendulum support. –  Remove the gear mechanism from the gearbox: → 02T 5 speed manual gearbox; Rep. gr.34 –  Remove the slave cylinder from the hydraulic clutch: → 02T 5 speed manual gearbox; Rep. gr.30   Note Clutch pedal must not be depressed. –  Drain coolant → Chapter.

–  Only remove the upper hose -2- of the coolant from the expansion tank. –  Disconnect connector -1-. –  Undo the securing bolts -3- and remove the expansion tank upwards. –  Pull coolant hoses off engine with spring-type clip pliers -VAS 5024A-.

–  Unscrew the nut -1- and expose the earth cable. –  Unscrew the bolts -arrows- in the gearbox mounting by approx. 2 turns .

–  Unscrew the bolts -arrows- in the gearbox mounting by approx. 2 turns . –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50 Vehicles with air conditioner –  Remove poly V-belt → Chapter.

–  Unplug electrical connector -2- at air conditioner compressor regulating valve -N280-.   WARNING The air conditioning 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. –  Remove bolts -arrow-, detach air conditioner compressor -1- with refrigerant lines connected and tie up to front.

–  Suspend the air conditioner compressor above with refrigerant hoses still connected, securing it with the securing tool -T10038- to the lock carrier plate. Take special care not to damage the system. –  Follow the additional instructions and assembly work → Chapter. All other vehicles continued –  Remove left and right-hand drive shaft from the gearbox and support in a raised position: → Running gear, axles, steering; Rep. gr.40.

–  Attach lifting tackle -2024 A- as follows and lift slightly with workshop crane: Pulley side: 1st hole on support bar in position 1 Flywheel end: 2nd hole on support bar in position 5.   Caution Use securing pins on hooks and locking pins -arrows- to avoid damage to engine and vehicle.   Note t  Marked items 1... 4 of the support bracket point to the pulley. t  The holes in the perforated flanges are counted starting from the hook.

–  Unscrew the screws -arrows- from the top right from the engine assembly and gearbox.   WARNING Nut -2- must not be loosened.

–  Unscrew the screws -arrows- from the top left from the engine assembly and gearbox.   Caution Danger of damage to hoses, pipes and wiring connections and to engine compartment. t  Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. t  Carefully guide the engine assembly until it is removed from the engine compartment. –  Pull out the engine assembly to the front During this procedure, turn and lower the engine assembly as necessary.   Note When the assembly is lifted out, it must be carefully guided to prevent damage to bodywork. Attaching engine to repair stand Secure engine to engine and gearbox support -VAS 6095- to carry out repairs. Operation process –  Unbolt gearbox. –  Secure engine on engine and gearbox support -VAS 6095-.