SEAT Workshop Service and Repair Manuals

Engine: Installing and removing, engine code letters BJB, BKC, BXE, BXF

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Hydraulic jack -SAT 1040-, see equivalent → Anchor

t	Torque wrench kit -SAT 8010-, see equivalent → Anchor

t	counterhold -T20205-, see equivalent → Anchor

t	counterhold -T10038-, see equivalent → Anchor

t	Centre guide -T10093-, see equivalent → Anchor

t	Collecting tray -T20173-, see equivalent → Anchor

t  Base -T20174-, see equivalent → Anchor   Note t  To carry out this work it will be necessary to disconnect battery earth strap. For this purpose, first check whether a coded radio is fitted. Where necessary, check the anti-theft coding first. t  The engine is removed from underneath together with the gearbox. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. t  Collect drained coolant in a clean container for re-use or disposal. t  Some components can not be removed, or only with a great deal of difficulty, while the engine is mounted. Therefore the event memory should be read out, to detect all the faulty components while the engine has been removed, and to replace them before the engine is reassembled. t  Before removing, read-out the event memory of all control units. t  Disconnect earth wire at battery with ignition switched off. Operation process   WARNING Observe safety precautions when disconnecting the battery → Electrical system; Rep. gr.27.

–  Disconnect battery earth cable -arrow- with ignition switched off.   WARNING Hot vapour/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open the cap of the coolant expansion tank.

–  Pull the oil dipstick -1- out of the guide tube. –  Lift the engine cover by the sides -arrows 2- and pull it out forwards -arrow 3-. –  Replace the oil dipstick in the guide tube.

–  Remove the electrical connector -2- from the air mass meter -G70-. –  Detach vent hose -1- and air duct hoses -3- and -5-. –  Remove bolt -4- and take out air cleaner housing.

–  Unscrew air duct at lock carrier -arrows-. –  Remove the battery → Electrical system; Rep. gr.27.

–  Remove the battery tray -arrows-.

–  Detach securing clips -1- and -2- on both selector cables.

–  Remove selector cable support bracket -arrows- from gearbox and place to one side.

–  Unscrew bolts -1- and -2-. –  Detach the line -arrow- from the bracket and move the slave cylinder to one side. Do not open the hydraulic system.

–  Disconnect the vacuum hose -arrow- in the servomotor.   WARNING Do not depress clutch pedal after removing slave cylinder.

–  Remove the protective cap of the magnetic switch, by pushing it in the direction of the -arrow-.

–  Unscrew the earth wire -1-. –  Remove the lines -2- and -3- of the starter. –  Remove front wheels.

–  Remove central noise insulation -Attachment parts 1 ... 3-.

–  Remove central noise insulation on the right and left side -Attachment parts 1 ... 3-. –  Place the drip tray -T20173- under the engine.

–  Remove air hose (right-side) by lifting retaining clips -arrows- slightly.   WARNING Cover the intercooler opening, for example, using a clean cloth made of spongy material so that coolant does not enter.

–  Disconnect the connector -2- from the coolant temperature sender -G83-. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection. –  Remove lower coolant hose -1-; to do this, pull out retaining clips.

–  Remove air intake hose (left-side) by lifting retaining clips -arrows- slightly.

–  Loosen the bolts -arrows- of the air duct.

–  Disconnect coolant hose at bottom of the oil radiator -arrows-, and drain off remaining coolant.

–  Unplug connector -1-.

–  Pull-off the connector -2- from the reversing light switch -F4-. –  Unscrew the nut -1- and take out bracket with electrical connections pin. –  Unclip bracket from wiring.

–  Remove the coolant hoses between the engine and the radiator -arrows- using the pliers -T20174-.   WARNING t  For those vehicles fitted with an injector pump, the temperature of the fuel and the fuel lines may reach up to 100 ºC in extreme cases. Before opening the duct connections, allow the fuel to cool otherwise there is a risk of severe burns. t  Wear eye and hand protection when performing any type of repair work on the fuel system!

–  Remove the fuel supply -3- and return -2- lines, and set aside. –  Remove coolant hose -1- and set aside. –  Remove air duct by lifting retaining clips -arrows- slightly.

–  Disconnect vacuum line -2- from the reserve tank. –  Disconnect the electrical connection -3- from the supercharger pressure sender -G31- –  Remove coolant hose -5-. –  Unscrew bolts -1- and -4- and remove the air duct along with the coolant hose.

–  Unscrew bolts -1- and -2-. –  Remove air hose (right-side) by lifting retaining clips -arrows- slightly.

–  Remove air hose from the turbo compressor by lifting retaining clips -arrows- slightly.

–  Detach hose connection element -2- from the hose assembly on the solenoid valve block by releasing retaining tab. –  Disconnect the vacuum hose -1- on the oil retention valve for the brake servo. –  Move the lock carrier in service position using the following components: → General body repairs, exterior; Rep. gr.50.

–  Disconnect fuel supply tube -3- and fuel return tube -2- by pulling on the release tabs.   Note Before removing the Poly-V belt, mark the direction of rotation using chalk or a marker. Running a used belt in the opposite direction could destroy it.

–  To slacken off poly V-belt, swivel belt tensioner in -direction of arrow-.

–  Immobilise the tensioner of the Poly-V belt with the counterhold -T20167--arrow-. –  Remove poly V-belt.

–  Unplug electrical connector -2-. –  Unscrew electrical wiring -1- and clamp -3- and remove from alternator.

–  Screw out bolts -arrows- and remove alternator. –  Remove alternator upwards.   Note t  If the alternator is stuck on its support, tighten the fixing screw 2 turns less. t  Carefully tap the bolt heads with the flat side of the hammer (in this manner you release the alternator fixing clamps).   WARNING The air conditioning refrigerant circuit must not be opened.   Note To prevent damage to the air conditioning compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

–  Disconnect electrical connection -1- for magnetic coupling on air conditioner compressor. –  Remove compressor bolts -arrows-.

–  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.

–  Disconnect the coolant hoses from the heating system heat exchanger in the dashboard -arrows-.

Engine code letters BKC, BXE, BXF –  Detach coolant hoses -1- and -2- from exhaust gas recirculation cooler.

–  Detach electrical connector -arrow- from the intake manifold flap motor -V157- . Continued for all vehicles

–  Extract the bracket and remove the connector -arrow- from the Hall sender -G40-.

–  Unplug electrical connector -arrow- from the oil pressure switch -F1- –  Remove oil pressure switch.

–  Disconnect the connector -arrow- on the engine speed sender -G28- using the extractor -T10118-.   Note To unlock the connector without using the extractor -T10118-, press the connector in the engine speed sender using a screwdriver and using simultaneous levering movements, lift the releasing tabs using a small and thin wire hooks. –  Set aside the wiring harness.

–  Unplug the electrical connector -arrow- on the coolant temperature sender -G62-.

–  Remove the connector support from the glow plugs -arrow-

–  Disconnect the electrical connection -arrow- from the fuel temperature sender -G81- and place the electric cable to the side.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Disconnect main connector for unit injectors and move wiring harness clear.

–  Loosen the bolts -arrows- fastening the mountings to the engine by a couple of turns.

–  Loosen the bolts -arrows- fastening the mountings to the gearbox by a couple of turns.

–  Unscrew the bolts crossways -1 ... 3- and pull out the pendulum support.

–  Remove front crosspiece from vehicle underbody -arrows-.   Note The flexible pipe connection (de-coupling element) in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged. –  Unscrew the nuts on the double clamp -1-.

–  Unscrew reinforcement for the front tube of the exhaust system -arrows-.

–  Release the clip -arrow- and remove the exhaust pipe from the exhaust gas turbocharger.

–  Unbolt the exhaust system bracket -arrows-. –  Push the tightening clamp back in order to separate the front tube of the exhaust system.

–  Unscrew the link rod on the right of the stabiliser bar -arrow-.

–  Unbolt left and right drive shafts from gearbox flange and the intermediate bearing. –  Tie up left drive shaft upwards. –  Rotate the steering wheel all the way to the right. –  Pivot the right hand side drive shaft forwards and tie up on the longitudinal member, as shown in the image.

–  Bring the securing tool -T20205- with the hydraulic jack -SAT 1040- and turn the bolt -4- until it is parallel with the engine block. –  From the rear of the engine -A-, first insert the fixed column -1-, then adjust the mobile column -2- as necessary and then screw on the nuts -arrows-. –  From the front of the engine -B-, position the mobile column -6- and adjust the bolt -5-. –  Adjust the bolt -3- to immobilise the securing tool -T20205-.   Note To unscrew bolts for assembly mounting use stepladder.

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

–  Unscrew bolts of assembly mounting on the gearbox -arrows-.   Note t  Check that all hose and line connections between engine, gearbox and body have been detached. t  To avoid damage, guide the engine/gearbox mounting carefully when lowering. t  Pay special attention to the clearance for the air conditioning compressor. –  Carefully lower the engine and gearbox. –  Pull engine/gearbox assembly as far as possible forwards and lower it slowly downwards.